Senior Engineer, Process Development & Sustaining Engineering

Job Description

The Senior 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 Master's, or Bachelor'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

Function: Engineering
Experience Level: Mid-Senior Level