Senior Process Engineer - Automated Optical Inspection

About this role

We anticipate the application window for this opening will close on - 3 Sep 2026   Careers that change lives start here. Medtronic is a global leader in healthcare technology with a Mission to alleviate pain, restore health, and extend life. Our 95,000 employees work across more than 150 countries to put patients first — developing innovative medical technologies that improve the lives of 72+ million patients each year. Your unique talents will help shape the future of healthcare while building a career grounded in purpose, growth, and impact.

A Day in the Life At 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 Senior 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 Senior 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 4 years of relevant experience OR Master's degree with a minimum of 2 years relevant experience OR PhD with 0 years relevant experience.

Nice to Have • Hands-on experience with  Automated Optical Inspection (AOI)  systems, including optics, illumination, image acquisition, defect detection, and classification • 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

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