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 Developmen t • 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 engine