Manufacturing Design Engineer (Failure Analysis)

Job Title

Manufacturing Design Engineer (Failure Analysis)

Role Summary

Lead and execute failure analysis investigations for manufacturing and field issues, using materials characterization and analytical techniques to determine root causes and recommend corrective actions. Work hands-on in a lab environment and collaborate with process, product, and supplier teams to implement durable solutions and support production ramps.

Experience Level

Mid-level. Experience expectations vary by degree: PhD — entry to intermediate (0+ years), Master’s — typically 3+ years, Bachelor’s — typically 5+ years. Overall role aligns with a mid-career engineer (roughly 3–7 years experience depending on degree).

Responsibilities

Primary responsibilities focus on root-cause analysis, diagnostics, and cross-functional technical support.

• Plan and lead failure analysis investigations for contamination, materials degradation, coating/substrate damage, and supply-related material issues.
• Perform materials characterization using techniques such as SEM/FIB, TEM, EDS, SIMS, XPS, FTIR, Raman, UV‑Vis, optical microscopy, interferometry, and chromatography (GC/LC).
• Correlate analytical data with process history, manufacturing conditions, and field usage to develop root‑cause models and actionable conclusions.
• Develop and validate new test methods, analytical workflows, and characterization capabilities to improve diagnostic throughput and coverage.
• Collaborate with internal stakeholders on material selection, feasibility reviews, supplier qualification, and production ramp support.
• Document findings in technical reports and presentations; communicate results to engineering and business teams to influence corrective actions.

Requirements

Looking for hands-on materials characterization and structured problem-solving skills. Degree requirements are summarized separately under Education Requirements.

• Must-have: Demonstrated hands-on experience in failure analysis and materials characterization; proficiency with instrument fundamentals and data interpretation.
• Must-have: Practical experience with one or more of SEM/FIB, TEM, SIMS, XPS, FTIR, Raman, UV‑Vis, and optical microscopy.
• Must-have: Ability to correlate analytical results with process and field data and to form evidence-based root-cause conclusions.
• Must-have: Experience applying structured problem‑solving / root‑cause methodologies (e.g., 8D) in a manufacturing or high‑reliability environment.
• Must-have: Strong written and verbal communication skills and experience working in multidisciplinary teams.
• Nice-to-have: Experience with contamination control, coatings, metallurgy, optical/mechanical systems, or semiconductor manufacturing processes.
• Nice-to-have: Experience with supplier qualification, production ramp support, and developing analytical workflows.
• Other: Willingness to travel for training, supplier engagement, project execution, and global support.

Education Requirements

Degree options stated in the posting: Doctorate (PhD), Master’s, or Bachelor’s in Materials Science, Chemistry, Chemical Engineering, or closely related technical fields. The posting specifies experience thresholds by degree: PhD with 0 years, Master’s with 3 years, Bachelor’s with 5 years.

About the Company

Company: KLA

Headquarters: Chennai, India

KLA is a global leader in diversified electronics for the semiconductor manufacturing industry. The company enables the production of electronic devices by inventing systems and solutions for manufacturing integrated circuits, wafers, and displays. With over 40 years of experience, KLA invests heavily in innovation and R&D to support advanced chip design and manufacturing process optimization, collaborating with top technology providers to deliver future electronic devices.