Principal Manufacturing Process Engineer

FormFactor•Farmers Branch, TX

19d

About The Position

FormFactor is seeking a Principal Manufacturing Process Engineer to support and improve photolithography and etch processes in a high-volume semiconductor manufacturing environment. Working under general supervision, the engineer will sustain manufacturing operations, execute process improvement initiatives, analyze process performance, and drive continuous improvements in yield, quality, throughput, and cost. The role partners with Manufacturing, Equipment Engineering, Quality, Facilities, Supply Chain, and R&D to characterize processes, investigate manufacturing issues, support new product introductions, and implement process enhancements that meet operational and customer requirements. The regular hours are day shift. The role also supports quality and compliance activities, engineering projects, process and technology transfers, equipment installations and qualifications, and communication of engineering findings to stakeholders. The position calls for experience in manufacturing process improvement and a data-driven, structured approach to problem solving.

Requirements

At least 5 years of related experience with a bachelor’s degree; or 3 years with a master’s degree; or a PhD without experience; or equivalent work experience.
Skills in adaptability, analytical thinking, communication, continuous improvement, data-driven decision-making, data visualization tools, attention to detail, Manufacturing Execution Systems (MES), Microsoft Office, problem solving, root cause analysis (RCA), and troubleshooting.
Ability to work in a fast-paced environment.

Nice To Haves

Experience supporting semiconductor wafer fabrication, photolithography, etch, thin film, plating, metrology, MEMS, advanced packaging, assembly, test, or other precision manufacturing processes.
Experience sustaining and improving manufacturing processes to achieve safety, quality, yield, throughput, and cost objectives.
Experience supporting process transfers, technology transfers, new product introductions (NPI), or manufacturing scale-up activities.
Experience implementing CAPA and continuous improvement initiatives.
Experience working within documented quality systems and regulated manufacturing environments.
Familiarity with ISO 9001, IATF 16949, AS9100, ISO 13485, or similar quality management systems.
Six Sigma Green Belt certification or equivalent continuous improvement training.

Responsibilities

Support characterization, optimization, and control of photolithography and etch manufacturing processes.
Monitor process performance and analyze data to identify trends, opportunities, and process variation.
Use Statistical Process Control (SPC) and process capability metrics (Cp/Cpk) to maintain stable processes.
Assist with designing, executing, and analyzing Design of Experiments (DOE).
Investigate process excursions, defects, and yield losses using structured problem-solving methods; perform root cause analysis and implement corrective and preventive actions (CAPA).
Support process validation, qualification, and change management activities.
Conduct risk assessments using PFMEA, control plans, and related methodologies.
Develop and maintain process documentation, operating procedures, specifications, and work instructions.
Create and maintain process dashboards, KPIs, and manufacturing performance reports.
Participate in Lean Manufacturing, Six Sigma, Kaizen, and other continuous improvement initiatives focused on efficiency and waste reduction.
Identify opportunities to improve process capability, cycle time, throughput, and equipment utilization; contribute to cost reduction and productivity efforts.
Assist with capacity planning and manufacturing optimization activities.
Implement error-proofing (Poka-Yoke) solutions and develop standard work practices to improve quality and operational consistency.
Support quality management system and applicable industry-standard compliance.
Participate in change control, process audits, and documentation reviews; assist with nonconformance investigations and corrective actions.
Support calibration programs and Measurement System Analysis (MSA/GR&R) activities.
Ensure manufacturing processes comply with internal procedures and regulatory requirements.
Lead or support small-to-medium scope engineering projects.
Collaborate with Manufacturing, Equipment Engineering, Quality, Facilities, Supply Chain, and R&D teams to resolve technical challenges.
Work with equipment vendors, suppliers, and contractors on process-related improvements.
Support capital equipment installations, qualifications, process transfers, and technology transfers.
Prepare technical reports, presentations, and engineering recommendations for stakeholders.