Sunnyvale, California, United States
• Owned system design for key modules including MLB/Speaker, Magnetic Dock (Car Mount), Action/Mute Button, and LED Lightbar with ALS system.
• Drove product from concept through xVT, to mass production in collaboration with cross-functional teams (ID, EE, Audio, RF, MDE, AME, Quality, Packaging).
• Led root cause investigations for complex reliability and FATP issues using DoE, FEA, CT/X-ray, FTIR/SEM, mold flow, and tolerance analysis.
• Resolved issues including USW cosmetic defects, mic sealing, speaker buzz, button tactility, and lightbar uniformity.
• Spearheaded vendor, CM, and JDM communications for DFM, FAI/Cpk/SPC, assembly SOPs, and fixture design, ensuring FATP readiness.
• Diagnosed and resolved ESD failures using dye ingress and CT scans; implemented USW joint optimizations and grounding strategies.
• Designed crush ribs and USW energy directors to meet 0.2 mm gap/step targets; added CTF/FAI controls, enabling 99% yield at mass scale.
• Developed 2-shot TPU-PC overmolded housings and adhesive stack-ups to meet reliability under variable surface curvatures.
• Engineered magnetic flux guides with N52 magnets, boosting retention force by +25% and reducing BOM cost to meet product viability.
• Validated soft tool mods and mold gate changes to eliminate TPU cracking from trapped air, preventing a major OK2Ship delay.
