Alessandro Mustaccio

Responsible for development of high-volume production processes for new products. Develop and verify appropriate and robust manufacturing processes. In parallel, investigate opportunities to test, develop and introduce new technologies, materials, equipment and processes that can increase efficiency in future production.

• Setup and execution of all lithographic processes such as coating/laminating, exposure, development, etc.
• Fabrication of new printhead MEMS chips, followed by analysis, interpretation and presentation of results.
• Develop and evaluate new process flows and production solutions in the cleanroom for technical and economic feasibility.
• Management and maintenance planning of cleanroom, one-room tools and equipment (including procurement planning of consumables and spare parts).
• Participation in research and development projects initiated by customers or with partners.
• Participate in production and internal cleanroom projects (microfabrication and printhead packaging).

Activities and responsibilities in lithography area:

• Evaluation and qualification of new Equipments and materials;
• Ordinary maintenance of lithography tool:
• SüssMicroTec MA200 Gen3; SüssMicrotec ACS200 Gen3 Coater & Developer;
• Responsible for working instructions and their implementation;
• Failure analysis and troubleshooting;
• 2nd level Technical support for wafer/chip fabrication and equipments to ensure a smooth production process;
• Training of the production staff for the best plants/processes;
• Implementation and promotion of the continuous improvement;
• Implementation of improvement projects on behalf of the management;
• Support the R&D group in the transfer and integration of new processes and technology from the development phase to the production phase.

Activities and responsibilities in lithography area:

• 1st level Technical support for wafer/chip fabrication and equipments to ensure a smooth production process
• UP or DOWN system decision and reprocessing management
• Make adjustments in process flow (e.g. post scrap)
• Communication with the shift supervisor and planner
• Training of the production staff for the best plants/processes
• Quality monitoring of processes and products
  
• Execution of complex and new processes not running in production (e.g. Non-Recurring Engineering)
• Supporting product and development engineering for the transfer of new equipment, processes and products from development to production
• Maintenance and calibration of production equipment.

Activities and responsibilities:

• Development of new processes in the areas of printed electronics (inkjet & screen printing) and micro-nano surface structuring
• Planning of routine and preventive maintenance for equipment and infrastructure
• Constant monitoring of environmental conditions (pressure, humidity, temperature, contamination)
• Evaluation and acquisition of new equipment
  
• Optimization and cost reduction related to external services and spare parts

Achievements

• By installing a monitoring system, implementing a maintenance and control plan and raising awareness among cleanroom users, there has been a general improvement in cleanroom conditions in terms of environmental stability and contamination.
• Reducing equipment downtime by implementing a maintenance plan and properly training operators
• Reducing costs by optimizing operations and evaluating various suppliers of materials and services
  

Activities and responsibilities during the start-up phase:

• Ensuring the construction of the analysis laboratory according to the established deadlines
• Supporting the Sharp Team for the installation of electrical analysis and characterization equipment for photovoltaic modules (sample preparation, QE, light degradation).
• Preparation of general documentation on equipment and processes and analysis steps
• Successful transfer of the skills acquired during the training in Japan to new colleagues and production groups

Activities and responsibilities after the start-up phase:

• Support to the Engineering Group and Production Group for troubleshooting and yield improvement through the electrical characterization of new processes and the control of production lines
• Calibration and maintenance of reference and production solar simulators. Maintenance of the analysis laboratory.

Activities and responsibilities:

• Characterization and consolidation of new processes in the area of NanoImprinting, Electron Beam and Screen Printing
• Evaluation and acquisition of new equipment
• Prototype and small production runs for customers
• Morphological analysis using SEM and optical microscopes.

Activities and responsibilities:

• Support to the R&D Group for the characterization, consolidation and manufacturing transfer of new technologies in the Lithography Area
• Creation of new measurement and process recipes for the characterization of new materials, data acquisition and data transfer to the R&D Group.
• Supporting production during the transfer of new products after the development phase
• Recipe optimisation and monitoring of specification parameters.

Activities and responsibilities:

• Control of the packaging and pasteurization process
• Evaluation and release in production of the new line for fresh cream and milk and of the packaging machines
• Ordinary maintenance of production line and packaging equipment
• Laboratory checks of product specification parameters to be processed