Process Development Engineer

FormFactor Inc.•Livermore, CA

1d•$75,400 - $99,015

About The Position

FormFactor is seeking a Process Development Engineer to support development, characterization, and commercialization of new products, materials, and manufacturing technologies. The role focuses on creating, testing, optimizing, and scaling manufacturing processes from research and development through pilot production and full manufacturing implementation. Working under general direction, the engineer applies engineering principles, statistical analysis, and experimental methodologies to develop robust manufacturing processes that improve product performance, quality, yield, and manufacturability. The role collaborates with R&D, Manufacturing, Product Engineering, Quality, Equipment Engineering, and external suppliers to evaluate technologies, develop processes, and support new product introductions. The position works in a fast-paced, high-technology environment and supports innovation and next-generation products. Regular hours are day shift. The role is located in Livermore, California, and pays $75,400 to $99,015 per year, depending on experience, skills, and background. The position requires no previous professional experience.

Requirements

Bachelor's degree in Mechanical Engineering, Materials Science, Chemical Engineering, Manufacturing Engineering, or a related engineering discipline.
No previous professional experience required.
Engineering experience in process development, manufacturing engineering, product development, or a related technical field.
Experience using statistical analysis techniques, DOE methodologies, SPC, and process capability tools.
Strong analytical and problem-solving skills, including troubleshooting complex manufacturing or development challenges.
Ability to work effectively in cross-functional environments and manage multiple priorities.

Nice To Haves

Cross-disciplinary education or experience spanning materials, manufacturing processes, equipment, and product development.
Hands-on experience developing and scaling manufacturing processes from R&D through production.
Demonstrated success transferring processes from R&D into manufacturing.
Experience in semiconductor, electronics, advanced materials, MEMS, precision manufacturing, or related industries.
Experience developing adhesive, dispensing, assembly, packaging, or automation processes.
Knowledge of process qualification methodologies, risk assessments, PFMEA, and change control practices.
Proficiency with JMP, Minitab, Python, Excel, or similar engineering data analysis tools.

Responsibilities

Develop, evaluate, and implement manufacturing processes, materials, and technologies for new product initiatives.
Conduct technology assessments and feasibility studies for next-generation products and manufacturing methods.
Design and execute process development plans to move concepts from laboratory and pilot phases into production-ready solutions.
Perform hands-on engineering to establish, optimize, and sustain manufacturing processes.
Design, execute, and analyze experiments using Design of Experiments (DOE) methodologies.
Characterize products, materials, equipment, and process outputs against customer and engineering requirements.
Use statistical analysis, process capability studies, and Statistical Process Control (SPC) to evaluate process performance.
Analyze process data to identify trends, root causes, and improvement opportunities.
Support New Product Introduction activities from concept development through manufacturing release.
Collaborate with cross-functional teams to develop scalable manufacturing solutions meeting cost, quality, reliability, and schedule objectives.
Assist with product and process qualification, validation testing, and process capability assessments.
Support pilot builds and manufacturing readiness for new products.
Transfer new processes and technologies from R&D into manufacturing environments.
Create and maintain work instructions, process flows, specifications, training materials, and related documentation.
Train manufacturing teams and facilitate cross-functional knowledge transfer.
Troubleshoot process-related issues and implement corrective and preventive actions.
Develop and integrate process modules and equipment into existing production platforms.
Support specialized assembly process development, including adhesive and epoxy dispensing applications.
Work with equipment vendors, suppliers, and fabricators to source, evaluate, and improve materials and tooling.
Participate in equipment selection, qualification, and acceptance activities.
Identify and implement improvements to yield, quality, throughput, reliability, and cost.
Prepare technical reports, presentations, risk assessments, and engineering recommendations.
Collaborate with Manufacturing, Quality, Supply Chain, Product Engineering, and R&D to drive project outcomes.