Process Control Engineer – Semiconductor Wafer Fabrication

Process Control Engineer Semiconductor Wafer Fabrication

Location: Ahmedabad, Gujarat, India

Work Mode: Onsite

Experience: 6 -15 Years

Role Overview

We are seeking an experienced Process Control Engineer to establish, implement, and continuously improve process control methodologies for an advanced semiconductor wafer fabrication facility. This role is responsible for monitoring manufacturing process stability, reducing variability, improving yield, and ensuring production processes consistently meet quality and technology requirements.

The Process Control Engineer will partner with Process Integration, Lithography, Thin Film, Diffusion, Ion Implant, CMP, Etch, Wet Process, Yield Engineering, Device Engineering, Equipment Engineering, Manufacturing, Automation, Metrology, and Quality teams to implement Statistical Process Control (SPC), Advanced Process Control (APC), Fault Detection and Classification (FDC), Run-to-Run (R2R) control, and data-driven manufacturing improvements.

The successful candidate will possess strong expertise in semiconductor manufacturing analytics, statistical modelling, process capability analysis, manufacturing automation, and continuous improvement.

Role Objectives

• Establish world-class semiconductor process control systems.
• Improve process stability and manufacturing capability.
• Reduce process variation and manufacturing defects.
• Support technology transfer and production ramp.
• Enable high-yield, high-volume semiconductor manufacturing.

Key Responsibilities

• Develop and implement process control strategies across semiconductor manufacturing operations.
• Establish Statistical Process Control (SPC) methodologies for critical manufacturing processes.
• Develop control plans for Lithography, Etch, Thin Film, CMP, Diffusion, Implant, Wet Process, and Metrology operations.
• Monitor process capability using Cp, Cpk, Ppk, trend analysis, and statistical monitoring techniques.
• Analyze manufacturing process data to identify variability, trends, and process excursions.
• Develop and maintain control charts, process dashboards, and manufacturing performance metrics.
• Implement Advanced Process Control (APC) methodologies to improve process consistency.
• Support Run-to-Run (R2R) process control implementation.
• Support Fault Detection and Classification (FDC) systems for early process deviation detection.
• Perform Design of Experiments (DOE) to optimize process capability.
• Drive root cause analysis for process excursions, yield losses, and equipment-related issues.
• Work closely with Process Integration and Yield Engineering teams to improve manufacturing performance.
• Develop process monitoring specifications for critical process parameters.
• Define Out-of-Control Action Plans (OCAP) and corrective action procedures.
• Support technology transfer and New Product Introduction (NPI).
• Collaborate with Manufacturing Execution System (MES) and Automation teams to integrate process monitoring.
• Support equipment qualification and process qualification activities.
• Develop engineering reports and present manufacturing performance metrics to leadership.
• Drive Lean Manufacturing, Six Sigma, and continuous improvement initiatives.
• Ensure compliance with semiconductor quality systems, ISO standards, and customer requirements.

Key Responsibilities During Fab Startup

• Develop baseline SPC strategy for the wafer fab.
• Define critical process control parameters for every process module.
• Establish process capability targets.
• Develop manufacturing dashboards and KPI reporting.
• Implement process monitoring systems.
• Support APC, R2R, and FDC implementation.
• Develop engineering documentation and OCAP procedures.
• Support qualification of production processes.
• Train manufacturing teams on SPC methodologies.
• Support high-volume manufacturing readiness.

Required Qualifications

• Bachelor's or Master's degree in Electronics Engineering, Electrical Engineering, Industrial Engineering, Statistics, Physics, Chemical Engineering, Materials Science, Semiconductor Engineering, or related discipline.
• 6 15 years of semiconductor wafer fabrication experience.
• Strong expertise in semiconductor process control and statistical analysis.
• Experience supporting high-volume semiconductor manufacturing.
• Proven expertise in SPC, APC, DOE, and process optimization.
• Excellent analytical, troubleshooting, and communication skills.

Technical Skills Semiconductor Manufacturing

• Semiconductor Wafer Fabrication
• Front-End Manufacturing (FEOL)
• CMOS Process Technology
• High Volume Manufacturing (HVM)
• Semiconductor Process Development
• Technology Transfer
• Process Qualification
• New Product Introduction (NPI)

Process Control Systems

• Statistical Process Control (SPC)
• Advanced Process Control (APC)
• Run-to-Run Control (R2R)
• Fault Detection & Classification (FDC)
• Manufacturing Process Monitoring
• Process Capability Analysis
• Process Variability Reduction
• Out-of-Control Action Plans (OCAP)
• Control Plans
• Manufacturing KPI Development

Statistical Methods

• Design of Experiments (DOE)
• Process Capability (Cp/Cpk/Ppk)
• Regression Analysis
• Multivariate Analysis
• ANOVA
• Control Charts
• Histogram Analysis
• Trend Analysis
• Correlation Analysis
• Predictive Analytics

Semiconductor Process Knowledge

Working Knowledge Of

• Lithography
• Thin Film
• Diffusion
• Ion Implant
• Etch
• CMP
• Wet Process
• Metrology
• Defect Inspection
• Yield Engineering

Automation & Manufacturing Systems

• Manufacturing Execution Systems (MES)
• Advanced Process Control Platforms
• Fault Detection Systems
• Equipment Automation
• SECS/GEM Communication
• Industry 4.0 Manufacturing
• Smart Factory Solutions
• Manufacturing Data Collection
• Factory Information Systems

Software & Analytics

• JMP
• Minitab
• Python
• SQL
• MATLAB
• Microsoft Excel (Advanced)
• Power BI
• Tableau
• Spotfire
• Statistical Programming

Metrology & Data Sources

• CD-SEM
• Overlay Metrology
• Film Thickness Measurement
• Particle Inspection
• Defect Inspection
• Electrical Parametric Test Data
• Equipment Sensor Data
• Inline Process Monitoring

Cross Functional Collaboration

The Process Control Engineer Will Work Closely With

• Process Integration Engineering
• Lithography Engineering
• Thin Film Engineering
• Etch Engineering
• CMP Engineering
• Diffusion Engineering
• Ion Implant Engineering
• Wet Process Engineering
• Yield Engineering
• Device Engineering
• Equipment Engineering
• Manufacturing Engineering
• Automation Engineering
• MES Engineering
• Metrology Engineering
• Product Engineering
• Quality Engineering
• Facilities Engineering
• Data Analytics Teams

Preferred Industry Experience

Experience Supporting Semiconductor Manufacturing For

• Logic Devices
• Memory Devices
• Foundry Manufacturing
• Analog & Mixed Signal ICs
• RF Devices
• Power Semiconductor Technologies
• Advanced CMOS Manufacturing

Candidates with experience in greenfield semiconductor fab startups, advanced technology nodes (28nm and below), Industry 4.0 implementation, or smart manufacturing environments are highly preferred.

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