Mark Dydyk Consulting

Operations & Engineering Executive

Fractional leadership for advanced manufacturing companies navigating scale-up, yield improvement, and operational stabilization.

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About

Mark Dydyk

40 years of leadership across semiconductor, medical device, and advanced manufacturing environments.

Mark Dydyk is an operations and engineering executive who specializes in manufacturing ramp, yield improvement, and operational stabilization for growth-stage and complex operations. His track record includes delivering over $20M in cost savings, 50%+ defect reduction, and large-scale capacity expansion across multiple industries.

As President of Mark Dydyk Consulting LLC, Mark partners with CEOs, COOs, and engineering leaders to stabilize operations, improve throughput, and build scalable manufacturing processes using Six Sigma-driven methodologies.

Mark holds a B.S. in Chemical Engineering from Arizona State University and is an ASQ Certified Six Sigma Black Belt (2003) and Certified Quality Engineer (2017).

Services

Manufacturing Ramp & Scale-Up

End-to-end process mapping, pFMEA development, and operations readiness assessments to de-risk production scale-up.

Yield Improvement

Six Sigma-driven root cause analysis, process optimization, and defect reduction programs that deliver measurable results.

Operational Stabilization

Interim executive leadership to reinforce quality systems, improve throughput, and build high-performance engineering teams.

Quality Systems & CAPA

Design and implementation of quality management systems, CAPA processes, and compliance frameworks for regulated environments.

Semiconductor & Wafer Fab

Deep expertise in wafer fab operations, equipment qualification, and process technology transfer across global sites.

Cost Reduction

Manufacturing footprint optimization, process automation, and operational efficiency programs delivering millions in annual savings.

Experience

Mark Dydyk Consulting LLC

President

Nov 2025 – Present

Provide fractional executive leadership to advanced manufacturing companies addressing scale-up risk, operational instability, and yield performance gaps. Partner with CEOs, COOs, and engineering leaders to stabilize operations, improve throughput, and build scalable manufacturing processes using Six Sigma–driven methodologies. Selected Engagement: Niron Magnetics (Advanced Materials / Scale-Up Manufacturing) • Partnered directly with process engineering to complete an end-to-end pFMEA, identifying and prioritizing high-risk failure modes prior to production ramp • Developed a full end-to-end manufacturing process map, defining inputs, outputs, and critical process parameters (CPPs) to align engineering, operations, and quality • Conducted a multi-domain operations readiness assessment, identifying gaps across equipment, process control, and organizational capabilities.

Heraeus Covantic

Process Engineering and Quality Manager

June 2025 – September 2025

• Short term assignment to stabilize operations, reinforce quality systems, and support engineering team performance during transition.

Medtronic

Director of Engineering and Operations

Feb 2023 – Apr 2025

Led a 24/7 semiconductor operations facility with 66 employees, managing engineering, operations, and maintenance. Spearheaded lean and Six Sigma initiatives, modernized equipment platforms, and built engagement systems that improved on-time delivery, reduced scrap, and enhanced workforce morale. • Achieved $2.5M in annual savings via overhaul of automated optical inspection criteria. • Boosted on-time delivery from 80% to 97% within 1.5 years. • Reduced NCRs by 50%, increasing product quality. • Launched New SPEA test platform and implemented closed-loop direct labor feedback program. • Transferred processes from obsolete to modern equipment platforms.

Medtronic

Equipment Engineering Program Manager

Aug 2017 – Oct 2019

Directed fab expansion programs and CAPA for Wafer Scale Operations. Improved equipment health, implemented automated material traceability, and enhanced vendor response times to bolster operational reliability. • Implemented automated material traceability system, eliminating NCMRs. • Upgraded fab infrastructure, including gas farms and chemical delivery systems. • Reduced vendor response times from weeks to less than 2 days for critical equipment. • Secured LINQ II equipment readiness with zero delays attributed to equipment infrastructure.

Medtronic

Senior Process Engineering Manager

October 2019 – February 2023

Managed a 24/7 team of 25 engineers and technicians supporting the LINQ II product line. Oversaw high-volume production, yield enhancement, and equipment qualification across critical device manufacturing stages. • Quadrupled output of laser battery bond process over two years. • Reduced final cycle time by 88%, from 18 to 2 days. • Increased laser battery bond yield by 20%. • Cut bonder qualification time from 3 months to 3 weeks.

Crocus Technology

VP Process Technology/Interim CEO

March 2014 – March 2017

Oversaw a $150M greenfield wafer fab build and startup. Delivered global ISO certifications and successful process transfers of cutting-edge TAS Magnetic sensors. • Delivered fab and equipment build on time and on budget. • Produced thousands of magnetic sensor prototypes. • Achieved ISO 9001:2008 certification across 3 global sites. • Navigated geopolitical and cross-cultural challenges

Crocus Technology

Director Program Management

Dec 2011 – March 2014

Led TAS-Magnetic sensor process integration through an IBM partnership. Delivered technology transfer and recipe development for successful prototype execution. • Produced thousands of TAS-Magnetic Sensor prototypes. • Managed IBM-Crocus development partnership and knowledge transfer. • Supported fab readiness for downstream commercialization.

Henkel

Director Operations Project/Global Quality

Dec 2008 – Nov 2011

Led global operations transformation post-acquisition. Consolidated manufacturing footprint and standardized quality systems across sites. • Consolidated 19 plants to 14, saving $21M/year. • Drove process equivalency and customer alignment through whitepaper validation. • Completed transformation ahead of schedule with a $30M budget. • Cut time-to-4D by 40%, 8D score improved 30%, and customer complaints down 25%.

Intel

Die Prep Technology Develpment Manager

Jan 2006 – December 2008

Developed Intel's next generation die prep process technology and transferred to production facilities worldwide. Managed team of 40 people; first line managers, engineers and technicians. • Led a team at Intel to develop die prep technology for next-gen CPU technologies, including ATOM (Intel's smallest form factor to date). • Implemented cost reduction projects, including an enlarged beam optics upgrade with auto-kerf. • Developed wafer singulation defect reductions, improving product reliability and reducing scrap.

Ablestik

Plant Manager

April 2003 – Jan 2006

• Led a team of 150 staff in manufacturing, warehouse, process engineering, planning, and maintenance at Ablestik Laboratories. • Implemented quality improvement initiatives resulting in Intel's preferred quality supplier award in 2006. • Oversaw the implementation of barcode technology and 5S methodology to enhance operations.

IQE

Equipment Engineering Manager

April 2002 – April 2003

Responislbe for equipment engineering, maintenance and facilities of IQE's Molecular Beam Epitaxy team.

Director of Engineering

ASM

June 2000 – March 2002

Led engineering organization to develop 300 mm ALCVD Pulsar Reactor. Supported 200 & 300 mm Epitaxy and RTCVD platforms. 75 person organization including equipment engineers, mechanical designers, process engineers, software engineers and equipment platform managers.

Motorola

Process Engineering Manager

July 1986 – June 2000

1986-1992 Bipolar 1 Wafer Fab 4" Process Engineer and Section Manager for Bipolar Analog Devices 1992-2000 Compound Semiconductor 1 III-V 6" Process Engineering Manager for RF Power Amplifiers. Managed team of 100 section managers, process engineers and maintenance technicians.

Results That Matter

$20M+

Cost Savings Delivered

50%+

Defect Reduction

88%

Cycle Time Reduction

20+

Years of Leadership

Let's Talk

Ready to stabilize operations, improve yield, or scale your manufacturing? Reach out to start a conversation.

markdydyk@gmail.com 415-373-2212 LinkedIn