Sr Manufacturing Process Engineer

FormFactor • Farmers Branch, TX

7d

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 uptime, yield, and throughput through structured troubleshooting, preventive and predictive maintenance, and data-driven continuous improvement aligned with FormFactor processes.

The engineer serves as process owner for assigned assembly and test tools, including precision alignment stations, adhesive and epoxy dispensing equipment, curing ovens, bonders, electrical test stands and handlers, and laser cutting equipment. The role supports equipment reliability, process qualification, documentation, data tracking, safety compliance, and operator and technician training.

Requirements

• Bachelor’s degree and at least 2 years of related experience, or an advanced degree without experience, or equivalent work experience.
• Knowledge or skills 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

• Own assigned assembly and electrical test tools and optimize their reliability and performance.
• Author and update standard work for equipment setup, qualification, operation, and maintenance.
• Troubleshoot equipment, fixtures, sensors, and PLC/HMI software issues using structured root-cause methods.
• Execute containment and corrective/preventive actions, 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, documenting learnings in equipment history logs.
• 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 in 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 insurance
• Long-term disability insurance
• 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