Lead, Thin Film Coatings Manufacturing Engineer

The Role: 

Our site in Bedford MA is seeking a Thin Film Coatings Project Engineer to join our team.  

In this role you will serve as the technical authority for coatings yield across our PECVD (Plasma Enhanced Chemical Vapor Deposition) and related deposition processes, owning the yield-improvement roadmap for our highest-loss process steps and delivering measurable, year-over-year improvement in yield performance. You will lead structured defect reduction and Six Sigma projects, drive process control and change management discipline, and mentor engineers on coating processes to build long-term coatings expertise in the organization. 

What You’ll Do:  

Yield Improvement & Defect Reduction  

• Own the coatings yield-improvement roadmap; set targets, track performance, and report progress against major rework, minor rework, and scrap yield loss.  

• Lead defect analysis for coating defects, find root cause, and permanent corrective action.  

• Prioritize yield loss using Pareto and cost-of-poor-quality analysis and translate findings into a project plan.  

Coatings Technical Leadership  

• Serve as a subject matter expert for PECVD and other thin film coating processes. 

• Support escalations on coating quality excursions. 

• Mentor engineers in the team on coatings technical knowledge. 

• Demonstrate ability to understand how PECVD and other coating tools operate, and perform fundamental troubleshooting of process to tool issues. 

Statistical Analysis & Process Control  

• Design and execute Designs of Experiments (DOE) to optimize critical process parameters and reduce variation.  

• Implement process controls to prevent recurrence of defects after root causes are corrected. 

• Establish Statistical Process Control on process parameters to detect yield failures proactively. 

Continuous Improvement & Six Sigma  

• Lead continuous improvement initiatives using Lean and Six Sigma (DMAIC) methodology to reduce variation, rework, and scrap.  

• Apply structured problem-solving tools such as 8D, 5 Whys, fishbone, FMEA, and control plans to sustain improvements.  

Project & Change Management  

• Own coatings projects end to end through the scope, plan, execution, qualification and implementation. Delivering to committed dates and business impact.  

• Lead validation and qualification (V&Q) activities and manage process, equipment, and material changes through the Management of Change processes, including risk assessment and customer notification where required.  

• Develop and release work instructions, control plans, FMEAs, and training content. Lead operator and technician training on new and revised coating processes.  

• Communicate technical findings, risks, and improvement roadmaps clearly to leadership, cross-functional partners, and customers.  

What We Seek: 

• BS or MS in Materials Science, Chemical Engineering, Mechanical Engineering, or a related engineering discipline, or equivalent experience.  

• 8+ years of process, yield, or manufacturing engineering experience, ideally in semiconductor or precision-materials manufacturing.  

• Demonstrated technical expertise in coatings technology, including PECVD (Plasma Enhanced Chemical Vapor Deposition) processes and thin-film deposition.  

• Proven track record of delivering measurable yield improvement and defect reduction in a high-mix production environment.  

• Strong statistical analysis capability, including SPC, DOE, capability analysis, and MSA, with proficiency in tools such as Minitab.  

• Expertise with Lean and Six Sigma methodology and structured problem-solving tools (8D, 5 Whys, FMEA, control plans).  

• Strong project management skills with the ability to lead cross-functional teams and manage multiple priorities.  

• Experience operating within a formal change management system.  

• Demonstrated leadership skills with the ability to influence, guide, and mentor engineers and operations personnel.  

• Excellent documentation, technical writing, and communication skills, with the ability to present technical information clearly to all levels of the organization and external customers. 

• Ability to work on the manufacturing floor and to thrive in a fast-paced operation.  

Outstanding Candidates Will Have: 

• Six Sigma Black Belt or Green Belt certification.  

• Direct experience with PECVD, PVD, or ALD coating processes. 

• Experience with coating metrology and inspection methods. 

• Experience owning yield in an industry with high quality expectation such as semiconductor. 

• A continuous improvement mindset and strong ownership of results.  

• Proven experience leading complex investigations, implementing process control systems, and improving stability and capability. 

• “Safety First” attitude practiced with integrity and a high degree of accountability for end results.