R&D Process Engineer - PECVD and Plasma Systems

Overview

The High Frequency Technology Center (HFTC) is seeking an R&D Process Engineer to develop, maintain and optimize manufacturing processes to fabricate passive interposer substrates for Keysight's Heterogeneous Integration technology. This position is onsite at Keysight Headquarters in Santa Rosa, CA. Live in beautiful Sonoma County amongst vineyards, redwood forests, rivers, lakes and coastline while working on state-of-the-art advanced packaging technologies.

The Process Engineer will own process development and process control to meet quality and production metrics. Responsibilities include a combination of R&D and manufacturing in partnership with Design, Integration, Test, Operations, Maintenance, Product and Failure Analysis teams. The Process Engineer is accountable for yield, cycle time, throughput, and quality of their process. This role involves technical depth in semiconductor processing, strong hands-on aptitude, as well as effective communication and teamwork to meet department-level objectives.

Process Development Engineers at HFTC are responsible for process development and sustaining of custom, cutting-edge, micro and nano-fabrication technologies.

The focus of this position is process development, manufacturing sustainability, and R&D support for new product introductions, with specialization in wafer fab processes.

Responsibilities include but are not limited to:

• Deep knowledge and expertise in wafer process development in one or more of the following areas, listed in order of preference: PECVD/CVD strongly preferred, followed by dry etch, PVD/sputtering, ashing, or similar vacuum-based processes.
• Own and advance plasma process performance across PECVD/CVD, dry etch, PVD/sputtering, and ashing tools by driving film quality, profiles, uniformity, selectivity, chamber health, defect reduction, and overall process robustness through structured DOEs
• Collaborate with equipment engineering on tool performance optimization, preventive maintenance strategies, throughput enhancements, and new tool installs or upgrades
• Drive process control and stability through SPC charting, daily reviews, root cause analysis, and corrective actions using statistical tools (e.g., JMP)
• Working closely with other process, integration, product, and circuit design engineers to define process and performance targets
• Defining process flows, develop new processes and drive continuous process improvement (CPI) efforts to maximize product yield
• Report process metrics, root cause investigations, and process change implementations at the department level
• Ensuring successful process hand off to manufacturing partners
• Working with Operations to implement robust process control and support production processes; diagnose and resolve process problems with urgency
• Leading capital equipment acquisition projects that include tool evaluation, characterization, process development, and qualification
• Broader experience in upstream and downstream processes and the ability to understand process interactions

Expertise in plasma-based semiconductor processes, with experience in PECVD/CVD strongly preferred, followed by dry etch, PVD/sputtering, ashing, and related vacuum-based processes.

M.S. or Ph.D. in Materials Science, Chemical Engineering, Physics, Chemistry, or related fields.

Exceptional recent M.S. or Ph.D. graduates with extensive cleanroom research experience and demonstrated expertise in plasma processes will be considered.

Proven experience in process development, Statistical Process Control (SPC), and Design of Experiments (DOE). Candidates must have experience establishing control charts from scratch, performing statistical analyses, and driving data-based process optimization.

Candidates must have strong problem-solving and analytical skills for measurement of anomalies and tool drift issues.

• 5+ years of industrial semiconductor process experience is strongly preferred.
• Candidates must have excellent interpersonal, verbal, written and presentation communication skills. The successful candidate must be able to communicate complex technical information in a clear, concise, and direct manner, present data effectively to both small and large audiences, and collaborate productively across cross-functional teams.
• Strong accountability, self-initiative and proactive attitude are required for success.
• Familiarity with vacuum systems, RF power delivery, gas flow control, and chamber hardware configurations.

This position requires access to certain goods, software, technology, or technical data subject to U.S. export control laws and regulations. Under these laws and regulations, U.S. persons (which includes U.S. citizens, U.S. nationals, lawful permanent residents, refugees, and asylees) working for Keysight can access export-controlled items without authorization from the U.S. government. For any individual…