Senior Quality Engineer

FormFactor•Farmers Branch, TX

23d•Onsite

About The Position

The Senior Quality Engineer is responsible for quality execution and continuous improvement for wafer fabrication processes at FormFactor’s Farmers Branch, Texas manufacturing site. The role supports process control, product quality, qualification, and compliance across fab operations, partnering with Process Engineering, Manufacturing, Equipment Engineering, Facilities, EHS, Supply Chain, and Operations. It is an experienced individual-contributor position requiring independent work on defined projects and escalations, and contributions to qualification, change control, and production ramp readiness. The engineer applies technical judgment and data-driven problem solving to improve wafer fab yield, process capability, contamination control, and defect performance. The role covers quality assurance and process controls, problem solving and continuous improvement, quality systems and compliance, technical guidance, and cross-functional collaboration. Regular working hours are day shift.

Requirements

At least 5 years of related experience with a bachelor’s degree; or 3 years with a master’s degree; or a PhD with no experience; or equivalent work experience.
Experience applying quality engineering methods and data-driven problem solving to wafer fabrication quality, process control, and continuous improvement.
Working knowledge of semiconductor fab controls, including SPC, control charts, process capability, measurement system analysis, tool qualification, tool matching, contamination control, and cleanroom discipline.
Knowledge of structured problem-solving methods, including 8D, 5-Why, Fishbone, fault-tree, and statistical methods.
Skills in change controls, containment, CAPA, cross-functional projects, data-driven decision making, MSA, process capability, process qualification, production tracking, RCA, and SPC.

Nice To Haves

Hands-on experience in one or more wafer fab process areas, such as photolithography, deposition, etch, plating, cleaning, metrology, inspection, or semiconductor chemical processes.
Experience with JMP, Minitab, or similar statistical analysis software and manufacturing execution or yield-management systems.
Experience supporting process transfers, tool installation and qualification, NPI, production ramps, or factory scale-up efforts.
Working knowledge of ISO 9001, semiconductor quality systems, cleanroom controls, and structured problem-solving methods.

Responsibilities

Support and improve quality performance for wafer fabrication processes, products, and process modules.
Establish, monitor, and improve controls for incoming materials, in-process controls, wafer inspection, and final quality acceptance.
Manage process excursions, nonconformances, material review, and disposition; support SPC, process capability, defect density, yield, and corrective and preventive actions.
Partner with Manufacturing, Process Engineering, and Equipment Engineering on production ramps, new process introductions, tool and process qualification, change control, and sustained high-volume fab operations.
Lead or support root cause analysis for process excursions, wafer defects, yield loss, contamination events, and customer escapes using structured and statistical methods.
Coordinate cross-functional corrective actions and verify their effectiveness.
Analyze SPC trends, process capability, defect paretos, tool matching, wafer maps, and yield data to identify risks and prioritize improvements.
Ensure adherence to quality systems, fab procedures, work instructions, control plans, and change-management requirements.
Support internal, customer, and third-party audits, including preparation, execution, evidence collection, and closure of findings.
Maintain and improve quality documentation, risk assessments, PFMEAs, control plans, qualification records, and reaction plans for wafer fab processes.
Apply quality engineering methods to wafer fabrication processes, including photolithography, thin-film deposition, wet and dry etch, plating, cleaning, metrology, inspection, and related chemical processes.
Provide technical guidance to engineers, technicians, operators, and inspectors on process control, defect reduction, containment, and acceptance criteria.
Apply semiconductor fab controls, including SPC, control charts, process capability, measurement system analysis, tool qualification, tool matching, contamination control, and cleanroom discipline.
Participate in PFMEA, control plan, process qualification, and change-review activities with Process Engineering.
Represent Quality in daily fab reviews, qualification meetings, change-control reviews, and escalation forums.
Partner with Operations, Process Engineering, Equipment Engineering, Facilities, EHS, Supply Chain, and leadership to contain excursions and mitigate process and product risks.
Communicate quality performance, technical risks, investigation status, and corrective-action progress to stakeholders.