Job Description
The Staff Engineer, Process Development & Sustaining will lead the development, optimization, and sustaining of manufacturing processes for WD's HDD storage products. This is a technically deep, cross-functional role requiring strong foundation in chemistry, materials science, or chemical engineering.
You will drive process characterization, chemical/material qualification, and yield improvement initiatives while ensuring manufacturing processes remain stable, compliant, and cost-competitive. You are expected to operate with high technical autonomy, interface with global R&D and process teams, and mentor junior engineers on the Penang floor.
This role is ideal for a PhD's, or Master's graduate in Chemical Engineering or Materials Science who is passionate about translating lab-scale science into high-volume manufacturing solutions.
Key Responsibilities
Process Development
- Design and develop new manufacturing processes or significantly improve existing ones for HDD production
- Conduct Design of Experiments (DOE) to characterize process windows, identify critical process parameters (CPPs), and optimize process outputs
- Evaluate and qualify new chemicals, materials, and process consumables for manufacturing use
- Develop process recipes, control plans, and standard operating procedures (SOPs)
- Translate R&D/lab-scale processes into robust, scalable, high-volume manufacturing processes
Process Sustaining
- Own sustaining engineering for assigned process modules — ensure processes remain stable, in control, and within specification
- Monitor Statistical Process Control (SPC) charts; respond to out-of-control signals with structured problem-solving
- Lead Engineering Change Orders (ECOs) for process changes, chemical substitutions, and material updates
- Manage process deviation requests and ensure timely resolution
- Maintain process documentation, control plans, and work instructions per WD QMS
Chemical & Material Engineering
- Lead chemical/material qualification activities including incoming material testing, process compatibility studies, and shelf-life evaluations
- Evaluate alternative chemistries and materials for cost reduction, sustainability, or supply chain risk mitigation
- Work with EHS team to ensure safe handling, storage, and disposal of process chemicals per regulatory requirements
- Support RoHS, REACH, and PFAS compliance reviews for process chemicals and materials
Yield & Quality Improvement
- Lead yield loss analysis and drive structured RCCA (Root Cause and Corrective Action) for process-related defects
- Apply Six Sigma / SPC / Lean methodologies to reduce process variation and improve Cpk
- Partner with Quality Engineering to resolve customer escapes and field returns linked to process issues
- Drive continuous improvement projects with measurable cost and quality impact
NPI & Technology Transfer
- Support New Product Introduction (NPI) process readiness — from process concept to mass production release
- Lead or support technology transfer of new processes from R&D/HQ to Penang manufacturing
- Develop process qualification protocols (PQ), installation qualification (IQ), and operational qualification (OQ) plans
Cross-Functional Collaboration
- Interface with R&D, Product Engineering, Quality, EHS, Supply Chain, and Equipment Engineering teams globally
- Present process data, findings, and recommendations to senior management and global stakeholders
- Collaborate with equipment engineers on process-equipment interactions and optimization
People & Mentorship
- Mentor and coach junior and mid-level process engineers
- Lead technical reviews, knowledge-sharing sessions, and engineering forums
- Support capability building within the Penang process engineering team
