Principal Manufacturing Process Engineer

FormFactor Inc.; Boulder (CO); On-site; USD 94,100 - 123,480; Full time

Benefits offered by this job

Medical Insurance

Dental Insurance

Vision Insurance

Life Insurance

Disability Coverage

401(k) with company match

ESPP

Paid Time Off

Profit-sharing Bonuses

FSAs

Job summary

FormFactor, Inc. in Boulder, Colorado, is seeking a Senior Manufacturing Process Engineer to lead complex process development, design transfer, and risk reduction across cryogenic and semiconductor test product lines.

Drawing on deep process engineering expertise, the role converts R&D knowledge into scalable manufacturing processes, guides junior engineers, and leads cross-functional problem solving to improve production quality, yield, and schedule.

Qualifications

• Minimum of 5 years of related experience with a Bachelor’s degree; or 3 years and a Master’s degree; or a PhD without experience; or equivalent work experience.

Responsibilities

• Lead complex process development and design transfer activities, converting R&D and prototype builds into validated, production-ready manufacturing processes.
• Define and execute process validation plans, readiness gate deliverables, and SOP development.
• Establish manufacturing methods for technically complex assemblies where processes are not yet fully defined.
• Own assigned manufacturing process areas with minimal oversight, including process definition, tooling/fixture requirements, documentation, and validation.
• Ensure processes are controlled, repeatable, and scalable across product lines.
• Independently solve manufacturing challenges of diverse scope and moderate-to-high complexity.
• Lead structured root cause investigations using methodologies such as 8D, 5 Whys, and Fishbone/Ishikawa diagrams.
• Drive corrective and preventive actions for recurring or complex process issues.
• Analyze manufacturing, quality, and yield data to identify trends and improvement opportunities.
• Lead continuous improvement initiatives using Lean/6S/PDCA methodologies.
• Establish and track KPIs; deliver measurable improvements in First-pass yield, defect reduction, cycle time, and rework rates.
• Conduct Design for Manufacturability (DFM) reviews with Product Engineering.
• Provide structured feedback on process risk, assembly complexity, and production feasibility.
• Represent Manufacturing Engineering in design reviews and technical forums.
• Identify and communicate manufacturing risks impacting quality, repeatability, or schedule.
• Partner cross-functionally to proactively develop and implement mitigation strategies.
• Develop and maintain comprehensive manufacturing documentation, including process flow maps, work instructions and travelers, and process qualification records.
• Establish and standardize best practices across product lines.
• Provide mentorship and technical guidance to junior engineers.
• Promote best practices in process engineering, documentation, and manufacturing standards.

Skills

Continuous Improvement

Cross‑Functional Collaboration

Cryogenic Systems

Data Analysis

Design for Manufacturing

ECO

GD&T

Manufacturing Process Design

Manufacturing Process Engineering

Manufacturing Process Validation

New Product Introduction

Process Development

PFMEA

Process Flow Documentation

Root Cause Analysis

Semiconductor Manufacturing

Writing Work Instructions

Education

Bachelor's degree in related field

Job description

Forming Our Future together

FormFactor, Inc. (NASDAQ: FORM), is a leading provider of essential test and measurement technologies along the full semiconductor product life cycle — from characterization, modeling, reliability, and design de‑bug, to qualification and production test. Semiconductor companies rely upon FormFactor’s products and services to accelerate profitability by optimizing device performance and advancing yield knowledge. The company serves customers through its network of facilities in Asia, Europe, and North America.

Rooted in our core values — Focus on the Customer, Ownership & Accountability, Respectfully & Effectively Communicate, and Motivate & Develop People — we foster an environment where diverse perspectives are not only welcomed but celebrated. Everyone can make an impact here. Whether it’s improving products, supporting customers, or positively influencing peers and the community, the contributions of our people matter.

Shift

The regular hours for this position are day shift.

Job Description

We are seeking a Senior Manufacturing Process Engineer to join our Boulder Operations team supporting the manufacturing of our Quantum Cryogenic product portfolio. This role independently owns complex manufacturing process development, design transfer, and technical risk reduction across cryogenic and semiconductor test product lines.

Drawing on deep process engineering expertise, this position converts R&D and prototype knowledge into controlled, scalable manufacturing processes. The role provides technical guidance to junior engineers and leads cross‑functional problem solving that directly impacts production quality, repeatability, and schedule. This engineer serves as a recognized technical authority within Manufacturing Engineering and contributes to advancing overall manufacturing readiness and process maturity.

Key Responsibilities

Process Development & Design Transfer

• Lead complex process development and design transfer activities, converting R&D and prototype builds into validated, production‑ready manufacturing processes.
• Define and execute process validation plans, readiness gate deliverables, and SOP development.
• Establish manufacturing methods for technically complex assemblies where processes are not yet fully defined.

Process Ownership & Execution

• Own assigned manufacturing process areas with minimal oversight, including process definition, tooling/fixture requirements, documentation, and validation.
• Ensure processes are controlled, repeatable, and scalable across product lines.

Problem Solving & Root Cause Analysis

• Independently solve manufacturing challenges of diverse scope and moderate‑to‑high complexity.
• Lead structured root cause investigations using methodologies such as 8D, 5 Whys, and Fishbone/Ishikawa diagrams.
• Drive corrective and preventive actions for recurring or complex process issues.

Data Analysis & Continuous Improvement

• Analyze manufacturing, quality, and yield data to identify trends and improvement opportunities.
• Lead continuous improvement initiatives using Lean/6S/PDCA methodologies.
• Establish and track KPIs; deliver measurable improvements in First‑pass yield, defect reduction, cycle time, and rework rates.

Cross‑Functional Collaboration & DFM

• Conduct Design for Manufacturability (DFM) reviews with Product Engineering.
• Provide structured feedback on process risk, assembly complexity, and production feasibility.
• Represent Manufacturing Engineering in design reviews and technical forums.

Risk Identification & Mitigation

• Identify and communicate manufacturing risks impacting quality, repeatability, or schedule.
• Partner cross‑functionally to proactively develop and implement mitigation strategies.

Documentation & Standards

• Develop and maintain comprehensive manufacturing documentation, including process flow maps, work instructions and travelers, and process qualification records.
• Establish and standardize best practices across product lines.

Leadership & Technical Guidance

• Provide mentorship and technical guidance to junior engineers.
• Promote best practices in process engineering, documentation, and manufacturing standards.

Work Environment

• Combination of office and laboratory/manufacturing floor environment.
• Ability to lift up to 25 lbs as needed.
• Use of standard office and lab equipment (computers, test setups, tools).
• Travel: Up to 15%.

Skills

Continuous Improvement, Cross‑Functional Collaboration, Cryogenic Systems, Data Analysis, Design for Manufacturing (DFM), Engineering Change Order (ECO), Geometric Dimensioning And Tolerancing (GD&T), Manufacturing Process Design, Manufacturing Process Engineering, Manufacturing Process Validation, New Product Introduction (NPI), Process Development (PD), Process Failure Mode Effects Analysis (PFMEA), Process Flow Documentation, Root Cause Analysis (RCA), Semiconductor Manufacturing, Writing Work Instructions

Education & Experience

Minimum of 5 years of related experience with a Bachelor’s degree; or 3 years and a Master’s degree; or a PhD without experience; or equivalent work experience.

Pay Range

$94,100.00 – $123,480.00 per year (Boulder, Colorado). Pay may vary in other locations.

Pay Range Explained

We offer a full benefits package, including medical, dental, vision, life insurance, disability coverage, a 401(k) with company match, employee stock purchase plan (ESPP), and paid time off. You’ll also be eligible for quarterly profit‑sharing bonuses and flexible spending or savings accounts.

Equal Employment Opportunity Statement

FormFactor is an equal opportunity employer. FormFactor complies with all national, state, and local laws that seek to promote equal opportunities for any applicant or employee without regard to age, race, color, gender, gender identity/expression, national origin, sexual orientation, religion, disability, marital status, pregnancy or related condition, military service, or any other legally protected characteristics. These protections apply to all aspects of employment, including but not limited to, recruitment, hiring, training, promotions, and compensation.

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