Process Engineer

FormFactor Inc.•Farmers Branch, TX

46d•Onsite

About The Position

The Process Engineer, Assembly & Test owns and optimizes assembly and electrical test equipment, used in the manufacturing of high-performing probe cards, to ensure safety, quality, and delivery (SQD) targets. Drive uptime, yield, and throughput by applying structured troubleshooting, preventive/predictive maintenance, and data-driven continuous improvement aligned with FormFactor processes.

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

Computerized Maintenance Management Systems (CMMS)
Electrical Testing Equipments
ESD Control
HMI Software
IQ OQ PQ
Measurement Systems Analysis (MSA)
Metal Bonding
Metrology
Precision Alignments
Process Failure Mode Effects Analysis (PFMEA)
Python (Programming Language)
Reading Schematics
Robotics
SPC Charts
Structured Query Language (SQL)
Vendor Management

Responsibilities

Serve as process owner for assigned assembly/test tools (e.g., precision alignment stations, adhesives/epoxy dispense, curing ovens, bonders, electrical test stands/handlers and laser cutting).
Author and update standard work (setup, qualification, operation) and maintenance work instructions.
Apply 5 Whys, Ishikawa, pareto analysis, and fault isolation to resolve equipment, fixture, sensor, and software PLC/HMI issues.
Execute containment and implement corrective/preventive actions (CAPA); verify effectiveness via run charts and capability checks (e.g., Cpk, GR&R for measurement systems).
Partner with Equipment Engineering to ensure equipment meets process windows (adhesive deposition, cure profiles, alignment tolerances, electrical test limits).
Propose and implement low-cost automation, poke-yoke fixtures, recipe optimizations, and error-proofing.
Participate in DOE and qualification (IQ/OQ/PQ) for equipment changes, capture learnings in the equipment history log.
Track uptime, yield loss by cause, first-pass yield (FPY), cycle time, and throughput; publish weekly dashboards.
Maintain calibration certificates, change control records, and risk assessments (PFMEA updates for equipment changes).
Ensure equipment complies with EHS (LOTO, machine guarding, ergonomics, chemical handling for adhesives/solvents).
Train operators/technicians on safe operations, preventive checks, and basic troubleshooting; verify training effectiveness with observations and signoffs.