Sr. Manufacturing Process Engineer

FormFactor Inc.•Boulder, CO

2d•$77,000 - $101,010•Onsite

About The Position

The Sr. Manufacturing Process Engineer supports mechanical build readiness, assembly process development, tooling and fixturing requirements, and work instruction quality for FormFactor's cryogenic and semiconductor test product manufacturing programs. Working under general supervision, this role serves as a critical link between engineering design documentation and manufacturing execution, ensuring production teams have the tools, processes, and documentation required to build assemblies safely, efficiently, and consistently. As a developing professional contributor, the Sr. Manufacturing Process Engineer applies manufacturing engineering principles to improve assembly processes, drive build readiness, support continuous improvement initiatives, and strengthen overall manufacturing capability. This position partners closely with Product Engineering, Test Engineering, Quality, and Production teams to ensure manufacturable designs, stable processes, and successful product builds.

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

5S Lean
Continuous Improvement
Cross-Functional Collaboration
Cryogenics
Data Analysis
Design Failure Mode and Effect Analysis (DFMEA)
Design for Manufacturing (DFM)
Electronic Assemblies
Fixture Design
Geometric Dimensioning And Tolerancing (GD&T)
Lean Six Sigma (LSS)
Manufacturing Processes
Mechanical Assemblies
Process Control Plans
Process Failure Mode Effects Analysis (PFMEA)
Process Flow Diagram (PFD)
Root Cause Analysis (RCA)
Statistical Process Control (SPC)
Work Instructions

Responsibilities

Support mechanical assembly readiness for assigned products and builds, including IQ3000, Quad Card, Flatiron, and other product lines, by reviewing engineering drawings, bills of materials (BOMs), assembly sequences, and manufacturing documentation for manufacturability and production readiness.
Identify, define, and document tooling, fixturing, equipment, and process requirements needed to support manufacturing activities; proactively identify risks and gaps before production schedules are impacted.
Develop and improve assembly processes that support safe, repeatable, and efficient manufacturing operations.
Support New Product Introduction (NPI) activities through manufacturing readiness reviews, process development, and production build support.
Apply mechanical design principles to develop fixtures, jigs, assembly aids, and tooling solutions that improve manufacturing efficiency, quality, and repeatability.
Create and modify CAD models, drawings, and related documentation to support manufacturing, testing, and process development requirements.
Evaluate tooling and fixture effectiveness and recommend improvements to support changing manufacturing needs.
Develop, maintain, and continuously improve work instructions, travelers, visual work aids, and manufacturing documentation that accurately define assembly processes and support consistent execution by production personnel.
Ensure manufacturing documentation remains current with engineering changes, process updates, and lessons learned from production activities.
Drive standardization of manufacturing processes by reducing reliance on undocumented tribal knowledge.
Work directly with production technicians and manufacturing personnel to understand build challenges, resolve process issues, and identify opportunities for improving efficiency, quality, and safety.
Provide Design for Manufacturability (DFM) feedback to Product Engineering, identifying assembly risks, process constraints, and opportunities to simplify manufacturing execution.
Partner with Product Engineering, Test Engineering, Quality, Supply Chain, and Operations teams to support successful product builds and process implementation activities.
Support implementation of engineering change orders (ECOs) and manufacturing process updates.
Apply structured problem-solving methodologies to resolve moderate-scope manufacturing and process-related issues.
Collect, analyze, and interpret manufacturing, defect, and process data to identify trends and improvement opportunities.
Support root cause investigations and corrective action activities related to process-related quality issues, production disruptions, and manufacturing escapes.
Lead or participate in continuous improvement initiatives utilizing Lean Manufacturing principles and structured improvement methodologies such as 6S, PDCA, and standard work.
Evaluate manufacturing processes for ergonomic, quality, safety, and productivity considerations and proactively address potential risks.
Ensure manufacturing processes comply with company quality standards, safety requirements, and established procedures.
Support process validation, qualification activities, and documentation reviews to ensure consistent and reliable manufacturing performance.
Escalate documentation gaps, manufacturing constraints, quality concerns, and schedule risks with recommended corrective actions.