Manufacturing Process Engineer, IRP RDA

PHOTRONICS INC•Boise, ID

9h•Onsite

About The Position

For more than 50 years, Photronics has been a global leader in photomask technology, powering the innovation behind the world’s most advanced devices. Our success is built on collaboration, quality, and the dedication of our people. We are hiring an IRP (Inspection, Repair, and Printability) Repair Engineer is a critical technical contributor within the photomask and photolithography operations team. This role is responsible for end-to-end quality assurance of photomasks and reticles used in advanced semiconductor manufacturing. From incoming defect inspection through focused ion beam (FIB) or laser-based repair, to final printability verification and yield impact assessment. The IRP Repair Engineer works in a cleanroom environment and collaborates closely with process integration, equipment, and lithography engineering teams to sustain and improve photomask quality, cycle time, and overall fab yield. This position requires a deep understanding of photolithography processes, mask defect physics, and related fabrication tools and equipment, combined with precision hands-on repair skills and strong data analytics capabilities.

Requirements

Bachelor’s degree in Electrical Engineering, Materials Science, Physics, Chemical Engineering, or related field

Responsibilities

Perform incoming and in-process inspection of photomasks and reticles using optical inspection systems operating in die-to-database and die-to-die modes.
Classify defect types (intrusions, extrusions, point defects, particles, phase errors) and assess severity and printability risk using CD-SEM, optical microscopy, and aerial image simulation tools.
Conduct reticle qualification checks per photolithography node specifications for various mask technologies.
Operate automated optical inspection (AOI) systems and analyze defect maps to distinguish systematic from random defect populations.
Execute precision defect repairs using focused ion beam (FIB) and/or laser-based repair platforms to remove opaque defects or restore clear defect areas on chrome-on-glass, EUV, and phase-shift mask types.
Determine repair dosage and etching parameters based on defect height, transmission, and reflection analysis; adapt repair recipes for leading-edge mask stacks.
Perform post-repair inspection and verification to confirm repair success and absence of collateral damage.
Manage repair cycle documentation including defect data, repair parameters, before/after images, and yield impact assessments.
Conduct printability analysis using AIMS (Aerial Image Measurement Systems) and lithography simulation tools to predict printed image impact from reticle defects before and after repair.
Collaborate with photolithography and process integration engineers to determine disposition of borderline defects: repair, use-as-is, or scrap.
Support mask qualification for new technology nodes and production processes, including review of critical dimension (CD) and overlay performance data.
Perform preventive maintenance (PM), calibration, and repair on photomask inspection and repair tools to sustain uptime and measurement accuracy per OEM specifications.
Troubleshoot electromechanical and optical system malfunctions; escalate complex tool issues to OEM field service engineers (ASML, Canon, KLA, Zeiss, Lasertec) as appropriate.
Maintain accurate maintenance logs, equipment status records, and spare parts inventory.
Analyze inspection and repair data using SPC (statistical process control) methods; identify trends, defect root causes, and systematic issues impacting mask quality and fab yield.
Apply design of experiments (DOE) methodology to optimize inspection parameters, repair recipes, and process controls.
Partner with process engineering on failure analysis investigations, implementing corrective actions to reduce defect density and improve mask cycle time.
Contribute to automation initiatives including scripted data extraction, auto-recipe generation, and reporting dashboards.
Author and maintain standard operating procedures (SOPs), work instructions, and qualification protocols for inspection, repair, and printability workflows.
Interface with photomask suppliers, OEM technical support teams, and internal process/integration engineers to resolve escalated quality issues.
Participate in cross-functional design-for-manufacturability (DFM) reviews, new product introductions (NPI), and technology transfer activities.
Comply with all cleanroom safety protocols, EHS standards, and export control (ITAR/EAR) requirements as applicable.