Summary
Overview
Work History
Education
Skills
Websites
Awards
Referrals
Timeline
Generic

Khairul Syafiq Merican B. Kamarudin

Senior Manager, PD Process Engineering (with Manufacturing Oversight)
Perai,Penang

Summary

15+ years of experience in semiconductor and LED industries, specializing in process development, manufacturing operations, and product engineering. Currently Senior Manager, PD Process Engineering (with Manufacturing Oversight) for L2 Flash Module; leading cross-functional teams in high-volume manufacturing (HVM). Process-oriented, enthusiastic problem solver with a proven ability to assess complex challenges, develop action plans, and drive teams to exceed targets. Certified Six Sigma Green Belt with strong execution in Design of Experiment (DOE), root cause analysis, and data-driven decision-making. Experienced in project initiation, stakeholder alignment, risk anticipation, and balancing triple constraints (schedule, requirements, cost). Hands-on leadership across the full product lifecycle, from early development through New Product Introduction (NPI), ramp, mass production, and End of Life (EOL). Strong in milestone buy-off, capacity planning, and ramp strategy for new product introduction. Known for adaptable and collaborative leadership, effective stakeholder engagement, and delivering impactful results in quality, cost, and efficiency. Seeking career growth in a diversified, technically-inclined managerial role that leverages engineering expertise, strategic thinking, and team development.

Versatile Senior Manager specializing in Backend Process Assembly in LED and semiconductor packaging and skilled at planning, implementing and overseeing key improvements to drive business growth and efficiency. History of cultivating an open culture with free exchange of information. Pursuing new professional challenges with a growth-oriented company.

Overview

13
13
years of professional experience
4
4
years of post-secondary education
2
2
Languages

Work History

Senior Manager, PD Process Engineering (with Manufacturing Oversight)

Lumileds Malaysia Sdn. Bhd.
04.2023 - Current
  • Reporting to: Senior Director, Development Engineering & Senior Director, Manufacturing Engineering
  • Scope: Initially responsible for Lens Attach and Metrology; expanded in Nov 2024 to include Sensor Attach, Wire Bond, and End of Line (EOL)
  • Promoted to Senior Manager in November 2024 following demonstrated success in NPI and Manufacturing delivery and team leadership; expanded scope to include Sensor Attach, Wire Bond, and EOL in addition to Lens Attach.
  • Successfully led multiple NPI launches for responsible Scopes with sustained yields >99.5% and no major excursions during ramp-up or mass production.
  • Drove cross-functional collaboration to resolve early-stage manufacturability challenges, enabling stable production for high-volume flash module programs.
  • Strengthened team capability through strategic realignment, establishing role clarity, NPI focus Scopes, and a support matrix to improve ownership and depth.
  • Implemented continuous process improvements addressing recurring module height (MH) defects, optimizing bonding hardware and process parameters.
  • Delivered operational wins by improving equipment uptime, meeting aggressive project timelines, and exceeding key metrics for yield and process stability.
  • Cultivated a proactive engineering culture with emphasis on accountability, technical depth, and structured problem solving.
  • Championed process mastery in Lens Attach by identifying top defect contributors and driving performance improvements aligned with 2024 and 2025 yield targets.
  • Directly responsible individual (DRI) for NPI and sustaining process engineering for Lens Attach.
  • Lead and develop a growing team comprising 7 engineers, 5 technicians, 5 engineering operators, and 1 process manager.
  • Ensure process readiness across all product milestones, meeting KPIs for yield, output, and machine capacity.
  • Oversee engineering project execution, cross-functional alignment (EPM, TPL, Ops, QE, EHS), and compliance with internal quality and safety standards.
  • Apply data analytics and statistical tools (DOE, SPC) to drive defect reduction, performance tracking, and yield optimization.
  • Provide coaching and performance oversight for engineers, instilling ownership, technical confidence, and continuous improvement mindset.
  • Manage NPI schedules, resource allocation, and stakeholder communication to ensure on-time, in-spec delivery of new products.

Manager, PD Process Engineering

Lumileds Malaysia Sdn. Bhd.
08.2022 - 03.2023
  • Reporting to: Director, Packaging and Process Development Engineering
  • Scope: Initially focused on dispensing process and technical project leadership; expanded in Aug 2022 to include Molding, Bead Blast, and Planarization.
  • Qualified a new dispensing side coat (DSC) material and process, meeting automotive reliability and optical specs, with projected cost savings of ~48% versus the previous OSC flow.
  • Enabled a locally sourced dispensing machine with 50% higher throughput and tighter tolerance, replacing aging tools with cost-effective alternatives.
  • Successfully assessed and qualified local mold cavity chase for overmold processes, offering a 70% cost reduction and securing future procurement flexibility.
  • Led process characterization and window studies for 4” tile leadframe-based products at OSC, achieving stable process performance and successful production readiness.
  • Introduced a new, lower-cost bead blast agent (27% savings) for IR products, leveraging previous learning to support material standardization.
  • Executed a detailed process window and interaction study for a flash module dispensing process with tight spatial constraints, enabling foundational learning despite project cancellation.
  • Acted as technical advisor for new dispensing-based process developments, including side coat, dam and fill, and encapsulation.
  • Led cross-functional development and release of new packages, including process characterization, material selection, and manufacturing readiness.
  • Managed a team of 3 Staff Development Engineers and served as the technical bridge between project teams and R&D.
  • Collaborated with Material R&D to assess alternative silicone materials for side coat and encapsulation, targeting both cost and manufacturability improvements.
  • Supported qualification builds, risk assessments, and documentation of process learnings for future roadmap development.

Staff Process NPI Engineer

ams Osram Opto Semiconductor (M) Sdn. Bhd.
11.2020 - 04.2021
  • Reporting to: Senior Manager, Development Engineering
  • Scope: Casting / Side Coating and Encapsulation dispensing process, Spray Coating process.
  • Successfully evaluated a new prototype spray gun that developed by Osram Regensburg team; utilizing DMAIC approach. The new spray gun able to produce tighter color spread.
  • Acted as the key interface between R&D process development and manufacturing, responsible for transitioning new and disruptive backend processes into production maturity.
  • Supported New Product Introduction (NPI) by driving continuous process improvements, yield optimization, and early risk mitigation to ensure stable ramp-up.
  • Collaborated cross-functionally to ensure readiness of equipment, process documentation, and control plans prior to full-volume transfer.

Senior Section Manufacturing Engineer

Boston Scientific Medical Devices (M) Sdn. Bhd.
04.2020 - 10.2020
  • Reporting to: Manager, Manufacturing Engineering
  • Scope: Urology fiber manufacturing line and packaging/boxing process.
  • Assigned to the Fiber product unit, responsible for developing and updating manufacturing documentation and procedures to ensure smooth production aligned with quality, yield, output, and cost targets.
  • Managed a team of 3 engineers covering the entire production flow from Fiber line to final boxing.
  • Supervised 5 technicians, overseeing daily operations, equipment availability, preventive maintenance (PM), and driving equipment improvement initiatives to support production efficiency.

Manager, Development Engineering

Lumileds Malaysia Sdn. Bhd.
04.2018 - 03.2020
  • Reporting to: Senior Manager, Development Engineering
  • Scope: Middle of Line (MOL) development – Dispensing, Encapsulation, Side Coating, Bead Blast, Planarization, and Automated Visual Inspection (AVI).
  • Successfully launched multiple high-volume products (automotive, flash, and converter-based) meeting >98% safe launch yield, including automotive 3030/3030LC and flash variants.
  • Led refurbishment and enablement of underutilized Asymtek dispensing machines to support new SMC leadframe-based products, eliminating the need for new CAPEX.
  • Established dam and fill process (silicone dispensing) for ceramic-based packages as interim solution before molding integration; process defined via DOE to control KPOVs.
  • Mentored and coached junior engineers on dispensing process fundamentals, enabling faster project ramp-up and support readiness.
  • As Manager, Development Engineering (2018–2020): Led a team of 4 engineers and 5 technicians in MOL process development activities across dispensing side coating, encapsulation, and Automated Visual Inspection (AVI) operations.
  • Acted as technical lead for all dispensing-related development, ensuring robust processes for new product launches.
  • Interfaced with global project leaders (San Jose, Penang) to align design intent, process capability, and production ramp planning.
  • Applied DMADV methodology to define and validate new equipment/process configurations for next-gen products.
  • Ensured manufacturing readiness through process stability, yield target achievement, and training execution.

Senior Product Development Engineer (Project Lead)

Osram Opto Semiconductor (M) Sdn. Bhd.
07.2014 - 08.2015
  • Reporting to: Senior Manager, Product Development Engineering
  • Scope: New Product Development and Project Management for Industrial LED (wall lighting) products.
  • Led end-to-end development of new LED products (Industrial wall light), from design to high-volume manufacturing.
  • Created optimized process flows and aligned product specs with customer requirements.
  • Drove issue resolution using structured problem-solving to minimize delays and rework.
  • Managed cross-functional teams to meet timeline, quality, and cost objectives.
  • Drove risk assessments, process readiness, and resolution of technical gaps.

Senior Process Development Engineer

Advanced Micro Devices (AMD) Export (M) Sdn. Bhd.
11.2012 - 07.2014
  • Reporting to: Section Manager, Process Development Engineering
  • Scope: Substrate Assembly (Underfill, Conformal Coating, TIM Dispensing, Lid Attach, Stiffener Attach).
  • Successfully qualified a new 2nd-source auto stiffener attach machine with no schedule slip to support Next-Gen gaming console readiness, improving capacity by 10%.
  • Qualified a hybrid attach machine for both stiffener and lid processes by validating process window and tooling requirements, enabling dual functionality.
  • Implemented Process Control System (PCS) for stiffener and adhesive dispensing to monitor key process inputs (KPIV) affecting outputs (KPOV), ensuring stability and predictability.
  • Optimized adhesive dispensing parameters using Design of Experiments (DOE), improving Units Per Hour (UPH) by 15% and reducing unplanned downtime by 3%.
  • Introduced new dispensing needle/tip design for stiffener adhesive process, improving UPH by 12%.
  • Qualified a semi-auto lid attach process and machine, replacing manual operation and improving throughput by 20%.
  • Led setup simplification for TIM and Indium Adhesive process, reducing setup and material changeover time from 15–18 minutes to 5–8 minutes (50% cycle time gain).
  • Successfully qualified new DEK stencil design for TIM printing, reducing material usage by 20–30% and saving ~USD 3M per quarter.
  • Improved DEK cycle time from 25–28s to 19–21s per boat, increasing throughput via process parameter optimization.
  • Drove automation of the conformal coating process, integrating inline systems to eliminate manual handling, saving 1 headcount per line.
  • Implemented a new dispensing pattern, achieving 7% capacity gain.
  • Evaluated and deployed improved nozzle design, increasing UPH by 10–12%.
  • Sustained conformal coating process for Indium/BSM packages to eliminate chip cap short issues, supporting material bulk feed conversion to reduce replenishment time and cut material cost by 50%.
  • Led underfill rework taskforce, reducing rework rate from 700ppm to below 300ppm.
  • Automated underfill weighing setup from manual to inline auto sequence, cutting setup time by 65%.
  • Contributed as a team member to preheat elimination project for underfill, saving USD 24K/quarter in electricity and 415.4 ft² of production floor space.

Education

Bachelor of Engineering (Hons.) - Mechanical Engineering

Universiti Sains Malaysia
Penang
06.2004 - 05.2008

Skills

  • Operations and Team Leadership

Adaptability and flexibility

Problem-solving abilities

Decision-making

Team collaboration

Problem-solving

Teamwork and collaboration

Team leadership

Data-driven decision making

Troubleshooting and problem resolution

Cross-functional team coordination

Operations management

Cross-functional communication

Data analytics

Cross-functional collaboration

Talent development

Resource allocation

  • Stakeholder Alignment

  • Technical Decision Making

  • Process Stability

  • Cost Reduction

  • Productivity and Efficiency Enhancement

  • Cross-Functional Project Leadership

  • Root Cause Problem Solving

  • Data Analysis

  • Continuous Improvement

  • Plan Do Check Act (PDCA) Cycle

  • Lean Principles

  • Six Sigma Methodology (DMAIC and DMADV)

  • High-Volume Manufacturing (HVM)

  • New Product Introduction (NPI) and Ramp-Up

  • Strategic and Risk Planning

  • Process Development and Optimization

  • Operations and Team Leadership

Awards

  • LUMILEDS: WW QIC, 2016, People Choice Awards for Project 3030 HP Development.
  • LUMILEDS: QIC LOCAL FINAL, 2016, Project Winner for Project 3030 HP Development.
  • AMD: GEM AWARD, 2014, Outstanding Performance for Gaming APU Enablement.
  • AMD: TEAM SYMPOSIUM, 2013, Top 3 Winner: End-of-Line Process Wastage Reduction.
  • AMD: IMS DEPLOYMENT, 2012, Pioneered the implementation of the Integrated Management System (IMS), comprising Process Control System (PCS), Recipe Management System (RMS), and One Touch Automation (OTA). This initiative significantly reduced process excursions and enabled faster response times by process engineers.
  • AMD: TEAM SYMPOSIUM, 2010, Top 3 Poster Winner: Underfill Process Yield Improvement.

Referrals

  • Dato' Dr. Mohd Sofi Bin Osman, Chairman & Independent Non-Executive Director, YBS International Berhad, Former Vice President, AMD and Lumileds (Former Superior), +60 12 422 6988
  • Mr. Thoe Chee Ming, Former Director, Packaging and Process Development Engineering, Lumileds (M) Sdn. Bhd., Former Superior, +60 16 452 3961
  • Mr. Saw Kok Siang, Senior Manager, Engineering, UTAC Group, Former Senior Manager, Development Engineering, Lumileds (M) Sdn. Bhd. (Former Superior), +66 94 882 8183
  • Mr. Thayalan Ainal, Director, Product Introduction and Engineering, ams Osram Opto Semiconductor (M) Sdn. Bhd., Former Superior, +60 17 627 0004

Timeline

Senior Manager, PD Process Engineering (with Manufacturing Oversight)

Lumileds Malaysia Sdn. Bhd.
04.2023 - Current

Manager, PD Process Engineering

Lumileds Malaysia Sdn. Bhd.
08.2022 - 03.2023

Staff Process NPI Engineer

ams Osram Opto Semiconductor (M) Sdn. Bhd.
11.2020 - 04.2021

Senior Section Manufacturing Engineer

Boston Scientific Medical Devices (M) Sdn. Bhd.
04.2020 - 10.2020

Manager, Development Engineering

Lumileds Malaysia Sdn. Bhd.
04.2018 - 03.2020

Senior Product Development Engineer (Project Lead)

Osram Opto Semiconductor (M) Sdn. Bhd.
07.2014 - 08.2015

Senior Process Development Engineer

Advanced Micro Devices (AMD) Export (M) Sdn. Bhd.
11.2012 - 07.2014

Bachelor of Engineering (Hons.) - Mechanical Engineering

Universiti Sains Malaysia
06.2004 - 05.2008

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Khairul Syafiq Merican B. KamarudinSenior Manager, PD Process Engineering (with Manufacturing Oversight)