Process Engineer

FormFactor•Farmers Branch, TX

13d•Onsite

About The Position

FormFactor is seeking a Process Engineer to support and improve photolithography and etch processes within a high-volume semiconductor manufacturing environment. Working under general supervision, the Process Engineer will assist in sustaining manufacturing operations, executing process improvement initiatives, analyzing process performance, and driving continuous improvements in yield, quality, throughput, and cost. This role partners closely with Manufacturing, Equipment Engineering, Quality, Facilities, Supply Chain, and R&D teams to characterize processes, investigate manufacturing issues, support new product introductions, and implement process enhancements that meet operational and customer requirements.

Requirements

Bachelor’s degree and a minimum of 2 years of related experience; or an advanced degree without experience; or equivalent work experience

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

Process Engineering Support characterization, optimization, and control of photolithography and etch manufacturing processes.
Monitor process performance and analyze data to identify trends, opportunities, and process variation.
Utilize Statistical Process Control (SPC) methods and process capability metrics (Cp/Cpk) to maintain stable processes.
Assist with the design, execution, and analysis of Design of Experiments (DOE) activities.
Investigate process excursions, defects, and yield losses using structured problem-solving methodologies.
Perform root cause analysis and implement corrective and preventive actions (CAPA).
Support process validation, qualification, and change management activities.
Conduct risk assessments utilizing 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.
Manufacturing & Continuous Improvement Participate in Lean Manufacturing and Six Sigma initiatives focused on efficiency and waste reduction.
Support Kaizen events and continuous improvement projects.
Identify opportunities to improve process capability, cycle time, throughput, and equipment utilization.
Contribute to cost reduction and productivity improvement efforts.
Assist with capacity planning and manufacturing optimization activities.
Implement error-proofing (Poka-Yoke) solutions to enhance quality and reduce defects.
Develop and sustain standard work practices that improve operational consistency.
Quality & Compliance Support compliance with quality management systems and applicable industry standards.
Participate in change control activities, process audits, and documentation reviews.
Assist in managing nonconformance investigations and corrective action implementation.
Support calibration programs and Measurement System Analysis (MSA/GR&R) activities.
Ensure manufacturing processes comply with internal procedures and regulatory requirements.
Project & Cross-Functional Support 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.