Sr. Staff Integration Engineer

FormFactor Inc.•Livermore, CA

34d•$163,400 - $214,410•Onsite

About The Position

The Sr. Staff Integration Engineer is responsible for defining, optimizing, and sustaining end-to-end process integration flows for probe card manufacturing in a high-volume semiconductor environment. This role serves as a senior technical authority, integrating complex unit processes across wafer-level fabrication, MEMS, precision assembly, interconnect, and electrical test. The position drives yield performance, manufacturability, and scalability by aligning cross-functional engineering, operations, and product teams. The role operates with significant autonomy, leading cross-module problem solving, technology transfer, and continuous improvement initiatives, while mentoring engineers and influencing integration strategy across sites. This role acts as the primary technical interface between process modules, ensuring integrated process flows meet product, quality, and reliability requirements.

Requirements

Minimum of 12 years of related experience with a Bachelor’s degree; or 8 years and a Master’s degree; or a PhD with 5 years experience; or equivalent experience.

Nice To Haves

8D Report
Change Management
Cross-Functional Groups
Cross-Functional Work
Data Analysis
Defect Metrology
Defect Reduction
Defects Analysis
Design for Manufacturing (DFM)
Design for Reliability (DFR)
Design of Experiments (DOE)
DMAIC
DMAIC Process Improvement
Electrical Failure Analysis
Electrical Validation
Electroplating
Etching
Failure Analysis
Manufacturing Execution Systems (MES)
Manufacturing Scale-Up
MES Integration
Metrology
Microelectromechanical Systems (MEMS)
New Product Introduction (NPI)

Responsibilities

Process Integration Ownership: Define, own, and continuously improve end-to-end process integration flows for probe card manufacturing. Ensure alignment of unit process performance to product-level electrical, mechanical, and reliability targets. Identify and manage integration risks, interactions, and trade-offs across modules.
Yield & Performance Optimization: Lead integration-level yield improvement initiatives using data-driven analysis and structured problem solving. Investigate complex yield excursions, defect mechanisms, and cross-process interactions. Drive defect reduction, process capability improvements, and cycle time reduction.
New Product Introduction (NPI) & Technology Transfer: Lead integration activities for NPI, pilot builds, and ramp to high-volume manufacturing. Own integration readiness criteria including process stability, control plans, and manufacturability. Support cross-site technology transfer and process replication with strong change control discipline.
Process Flow Development & Control: Develop and maintain integrated process flows, specifications, and control strategies. Define critical process parameters, control points, and monitoring strategies (SPC/FDC). Ensure robust process window characterization and documentation.
Cross-Functional Technical Leadership: Act as the technical integration interface across Process, Equipment, Product, Yield, Quality, and Manufacturing teams. Influence design for manufacturability (DfM) and design for reliability (DfR). Partner with operations on process stability, tool readiness, and production performance.
Data Analysis & Problem Solving: Analyze inline, electrical test, metrology, and defect data to identify integration gaps. Design and execute complex DOEs to resolve multi-variable process interactions. Utilize structured methodologies (DMAIC, 8D) for root cause analysis.
Change Management & Governance: Evaluate, approve, and implement changes to processes, materials, equipment, and flows. Ensure compliance with change control processes, qualification standards, and documentation requirements. Maintain traceability and configuration control across process changes.
Mentorship & Technical Influence: Mentor and guide junior and senior engineers on integration practices and problem solving. Provide technical leadership on cross-functional and multi-site initiatives. Influence long-term integration strategy and technology roadmap.