Principal Process Engineer - Automated Optical Inspection

Job description

We anticipate the application window for this opening will close on - 18 Jun 2026 At Medtronic you can begin a life-long career of exploration and innovation, while helping champion healthcare access and equity for all. You’ll lead with purpose, breaking down barriers to innovation in a more connected, compassionate world. A Day in the LifeAt Medtronic, we bring bold ideas forward with speed and decisiveness to put patients first in everything we do. In-person exchanges are invaluable to our work. We’re working onsite 5 days a week as part of our commitment to fostering a culture of professional growth and cross-functional collaboration as we work together to engineer the extraordinary. The Principal Process Engineer will be responsible for the development, integration, and optimization of wafer scale Automated Optical Inspection (AOI) systems from concept through release to manufacturing at our Medtronic Tempe Campus. This role will lead the definition of inspection strategies, platforms, and validation methods to ensure robust, scalable, and cost-effective inspection solutions that enable high-yield wafer scale manufacturing. The Principal Process Engineer will drive system-level integration by deeply understanding interactions between wafer fabrication processes, inspection hardware, optics, illumination, algorithms, data systems, and manufacturing operations. They will lead risk identification, mitigation, and burn-down activities using Design for Reliability Manufacturing (DRM) and data-driven methodologies. This role will also be responsible for managing validation activities, including requirements flow-down, control and monitoring strategies, and ensuring compliance with quality system and regulatory requirements. Responsibilities may include the following and other duties may be assigned. Lead the innovation, development, and optimization of wafer scale AOI processes and systems for transfer to manufacturing operations Champion the use of Design for Reliability Manufacturing (DRM) and data-driven methods throughout AOI system development Define and integrate inspection strategies, process flows, and design rules aligned with wafer fabrication and product requirements Collaborate with process owners, product development teams, equipment suppliers, and manufacturing to define robust, scalable AOI solutions Own requirements flow-down from product and quality requirements to AOI system capabilities, including inspection sensitivity, defect classification, throughput, and false-call management Develop, implement, and disposition control and monitoring strategies to ensure inspection effectiveness and manufacturability Own and manage AOI-related process validation deliverables at the product and system level Lead risk assessments and risk burn-down activities associated with inspection coverage, detection limits, data integrity, and system reliability Provide input to product and process design based on inspection capability, integration risks, and cost-of-quality considerations Apply statistical methods and science-based decision making to design experiments, optimize inspection parameters, and implement improvements Implement and own inspection performance and yield monitoring systems, including defect density, trend analysis, and excursion detection during development Monitor, root-cause, and resolve inspection-related yield and escape issues during development and ramp Review product development requirements for compatibility with inspection methods, influencing cost, cycle time, and schedules Ensure alignment between product design, wafer processes, and AOI system capabilities Generate and maintain technical and quality documentation in compliance with quality system regulations Ensure AOI processes, data systems, and procedures comply with applicable regulatory and quality requirements Must Have: Minimum Qualifications Requires a Baccalaureate degree and minimum of 7 years of relevant experience OR Master's degree with a minimum of 5 years relevant experience OR PhD with 3 years relevant experience. Hands-on experience with Automated Optical Inspection (AOI) systems, including optics, illumination, image acquisition, defect detection, and classification Nice to Have Experience with Design for Reliability Manufacturing (DRM), Design for Six Sigma, or Lean Six Sigma (Green/Black Belt preferred) Strong knowledge of DOE, statistical analysis, and data analysis tools (e.g., Minitab, JMP, Python, SQL) Demonstrated system-level problem-solving skills in complex manufacturing or inspection environments Experience with wafer fab integration and wafer scale manufacturing Experience developing and deploying inspection systems from concept through manufacturing transfer Familiarity with high-volume manufacturing environments and production-scale inspection challenges Experience working with equipment vendors and cross-functional engineering teams Advanced degree in Physics, Optical Engineering, Electrical Engineering, Mechanical Engineering, Materials Science, Chemical Engineering, Biomedical Engineering, or a related discipline For Baccalaureate degrees earned outside of the United States, a degree that satisfies the requirements of 8 C.F.R. § 214.2(h)(4)(iii)(A) is required. Physical Job Requirements The above statements are intended to describe the general nature and level of work being performed by employees assigned to this position, but they are not an exhaustive list of all the required responsibilities and skills of this position. The physical demands described within the Responsibilities section of this job description are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. For Office Roles: While performing the duties of this job, the employee is regularly required to be independently mobile. The employee is also required to interact with a computer, and communicate with peers and co-workers. Contact your manager or local HR to understand the Work Conditions and Physical requirements that may be specific to each role. U.S. Work Authorization & Sponsorship At Medtronic, we are committed to fostering an environment where employees can thrive and make a meaningful impact. In alignment with our enterprise-wide workforce planning approach, U.S. work authorization sponsorship (H-1B, TN, J, etc.) is offered exclusively for Principal-level roles and above, where specialized expertise aligns with long-term business needs. Roles below the Principal level require candidates to possess unrestricted U.S. work authorization at the time of hire and for the duration of employment. Join us in our mission to alleviate pain, restore health, and extend life—where your unique background and perspective are valued. Benefits & Compensation Medtronic offers a competitive Salary and flexible Benefits Package A commitment to our employees lives at the core of our values. We recognize their contributions. They share in the success they help to create. We offer a wide range of benefits, resources, and competitive compensation plans designed to support you at every career and life stage. Salary ranges for U.S (excl. PR) locations (USD):$128,800.00 - $193,200.00 This position is eligible for a short-term incentive called the Medtronic Incentive Plan (MIP). The base salary range is applicable across the United States, excluding Puerto Rico and specific locations in California. The offered rate complies with federal and local regulations and may vary based on factors such as experience, certification/education, market conditions, and location. Compensation and benefits information pertains solely to candidates hired within the United States (local market compensation and benefits will apply for others). The following benefits