Sr Manufacturing Process Engineer

FormFactor Inc. • Farmers Branch, TX

8d

About The Position

The Sr Manufacturing Process Engineer owns and optimizes assembly and electrical test equipment used to manufacture high-performing probe cards, ensuring safety, quality, and delivery (SQD) targets. The role drives equipment uptime, yield, and throughput through structured troubleshooting, preventive and predictive maintenance, and data-driven continuous improvement aligned with FormFactor processes.

The engineer serves as the process owner for assigned assembly and test tools, develops and maintains standard work and maintenance instructions, resolves equipment and process issues, and partners with Equipment Engineering to ensure equipment meets process windows. The role also supports equipment changes and qualifications, tracks performance metrics, maintains required records, and trains operators and technicians in safe operations and basic troubleshooting.

Requirements

• Bachelor’s degree and a minimum of 2 years of related experience; or an advanced degree without experience; or equivalent work experience.
• Skills or knowledge in Computerized Maintenance Management Systems (CMMS), electrical testing equipment, ESD control, HMI software, IQ/OQ/PQ, Measurement Systems Analysis (MSA), metal bonding, metrology, precision alignments, PFMEA, Python, reading schematics, robotics, SPC charts, SQL, and vendor management.

Responsibilities

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

Benefits

• Medical insurance
• Dental insurance
• Vision insurance
• Employee Assistance Program (EAP)
• Short-term disability
• Long-term disability
• Life insurance
• Flexible spending and savings accounts
• 401(k)
• Employee Stock Purchase Plan (ESPP)
• Paid time off

What This Job Offers

• Job Type: Full-time
• Career Level: Senior