Matt O'Leary

Collaborating with an excessively talented craftsman to deliver small volume builds of pediatric prosthetic running blades. Currently working on product portfolio selection and ISO testing that will allow our blades to reach high activity children with a lower cost barrier.

Leading multiple managers and teams through dynamic software and equipment deployments. Reporting key findings, including cost, benefit analysis and risks to CEO and our executive committee. Creating the systems necessary for successful installation, configuration, maintenance and adoption of school bus routing software, and its accompanying hardware. Delivered thousands of GPS, tablet, and Android software products with higher customer retention and satisfaction than historical averages. Kept clients engaged through meaningful collaboration, working to launch enhancements that met their own organization’s unique needs while also serving the needs of other clients. Authored hundreds of documents, business processes, work flows, and how-to-guides to steer continuous improvement, allowing my teams to extend their skills beyond monotonous maintenance and once-difficult troubleshooting. Adopted “golden” systems to ensure we could deliver consistent results on active deployments. Created VBA based systems to provide comparative analysis of configuration files for troubleshooting. Used this system to guide us through subsequent GPS development cycles and deployments. Performed hardware and software acceptance testing, communicating closely with vendors, manufacturers, and developers in order to provide data driven equipment direction for our company. Produced hundreds of tickets and phased plans to define development cycles for local and overseas development teams. Traveled to client locations to deploy, train, and troubleshoot equipment and software issues. Traveled to conference trainings to demo our newest software and equipment pairings.

Led Replacement Gate (RG) NAND in BS/Bevel Region E excellence. Adopted new vapor technologies as technically beneficial replacement opportunities were identified. Championed completion of Site Acceptance Criteria (SAC) for newly installed toolsets. Supported SPC excellence for RG NAND process control and monitoring. Worked closely with photolithography locally and globally to develop CMOS improvements to eliminate high voltage plasma etch arcing from a nearly 20% wafer hit rate. This methodology was noted as having the most preeminent bevel in NAND manufacturing history, while extinguishing the high cost of equipment replacement, maintenance, and downtime to the program. Drove H2H development and evaluation of vapor etch technologies between multiple vendors for a critical structure. Achieved millions of dollars of capital reduction through close collaboration with procurement. Succeeded in meeting construction specification requirements for uniformity by driving vendors to advance their process capabilities. Successfully led or assisted with multiple tool SAC evaluations. Through streamlining and improving resource utilization, was able to improve Time to Release (TTR) over historical methods. Through thorough analysis, was able to identify critical failures in the design or assembly of tools. Developed a wide array of skills across vapor etch (AMAT, TEL, LAM), bevel etch (LAM, DNS), spin clean (DNS, TEL), and plating tools (AMAT). Collaborated heavily across departments to ensure streamlined integration between departments.

Led multi-faceted teams of technicians and engineers through tactical and strategic endeavors involving multimillion dollar tools, tight deadlines, and cross-team collaboration. Drove continuous improvement and growth of each employee through timely and constructive feedback. Successfully maintained all safety related certification, and avoided any safety incidents. Quickly adapted to a new fab, new department, and role as a leader. Led multiple teams from within the department, gaining rapport from all groups within wet process and across departments. Represented Wet Process through cost meetings, within fab 4 and globally across fabs, helping to establish nearly $16M in global cost reduction initiatives at the 2016 Japan ZBA summit. Rolled out new software (DTS) to the fab teams, and built documentation and training alongside the release.

Maintain sole responsibility for ensuring quality, throughput, and process matching for a fleet of over 40 process chambers. Coached and mentored individuals, both informally and formally throughout employment. Led focus teams to attain specific goals aligned with company strategies. Developed new processes based on experimental designs and models in order to establish improvements directly relating to our bottom line. Created a more robust STI process by deep analysis of full spectrum optical emissions through the sequential film processing in order to facilitate high volume manufacturing capability across multiple, global facilities. The new process has led to better chamber matching, improved cd cpk, and better cross-pm performance. Conceived, designed, and launched a series of business processes and troubleshooting guides for statistical process control deviations (Engineering Reaction Mechanisms), for which there was no prior documentation. Guided the department in construction and administration for each level. Developed a constant cross-step temperature control gate recipe which has led to over a minute RPT reduction of the process. Led global and interdepartmental quartz defectivity focus team from problem discovery to full containment. Upon completion, this team resulted in a ~2% yield increase at mature yield. Led department as part of a site wide effort to improve cycling capabilities from the global worst to the benchmark facility. Was recognized with an Intel NSG award for excellence for my contributions. Successfully created and facilitated an offsite teambuilding event, including travel, events, logistics, and meals for over 90 team members. Coded a program which paired with Lam Data Analyzer, that allowed for the streamlined visualization of optical emissions, including time trend analysis and chamber to chamber variation. This software was in use by our top engineers for years after inception, saving hours of time on endpoint analysis.

Responsible for exploring changes to procedures, processes, machines, and environments to improve the quality of parts and/or increase throughput. Provided summaries of complex data sets and recommended process paths by analyzing inline and conversion data. Monitored critical metrics to ensure the area was operating efficiently, and worked with shift engineers and technicians to outline plans for resolving machine and process issues.

Responsible for engineering and production management including 12 engineers and technicians in the Dry Etch area during absence of the lead engineer. Responsible for following up on projects in a manner that displayed a thorough understanding of engineering and production issues. Supported process sustainment/development using thorough knowledge of data mining programs. Communicated issues, projects, and procedural changes to engineering and production groups.

Responsible for experiments and projects involving equipment failures and ISO certifications. Worked with technicians to develop new experimental valve testing. Designed experiments to determine modes and rates of failure of gas valves Tested valves from multiple vendors using helium leak detectors Engaged in research and recommendation of new equipment and vendors Analyzed historical tanker valve and pressure release device failures Compiled documentation from multiple sources to clarify equipment issues