Senior Process Engineering Lead – Semiconductor Manufacturing

FormFactor Inc.; Farmers Branch (TX); On-site; USD 180,000 - 230,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision care

EAP

Short-term disability

Long-term disability

Life insurance

401(k)

ESPP

Paid time off

Job summary

FormFactor, Inc. is launching a large‑scale startup operation in Farmers Branch, TX and seeks a Sr Manager of Process Engineering to lead all process development, optimization, and sustaining activities across a vertically integrated probe card manufacturing operation.

You will drive continuous improvement, develop a technology roadmap, and guide teams in fab processes, probe stitching, SMT, and vertical probe card assembly to meet performance and cost targets.

Qualifications

• Bachelor’s or Master’s degree in Engineering (Mechanical, Electrical, Materials, Chemical, or related).
• 10+ years of experience in semiconductor manufacturing, probe card manufacturing, MEMS, or similar high‑precision industries.
• Proven leadership experience managing engineering or technical teams.
• Deep expertise in process engineering, statistical analysis, and advanced problem‑solving.
• Experience in probe card manufacturing, MEMS probe technologies, or advanced micro‑assembly.
• Familiarity with SMT, micro‑joining, precision alignment technologies, and optical metrology.
• Understanding of reliability testing, thermal‑mechanical modeling, and electrical test correlation.
• Experience with factory automation, MES systems, and digital twins.
• Strong communication and ability to influence at engineering and executive levels.

Responsibilities

• Lead Process Engineering org across fab processes, probe assembly, SMT operations, and NPI.
• Define long‑term process technology roadmap aligned with R&D, Operations, and Quality.
• Drive talent development via growth plans, cross‑training and succession planning.
• Establish performance metrics (yield, Cp/Cpk, cycle time, OEE, defectivity) and drive improvements.
• Partner with Manufacturing Operations to own output, yield, and cost targets.
• Oversee fab process ownership including deposition, lithography, etch, metallization, planarization, cleaning, metrology.
• Lead qualification and integration of new fab equipment, chemistries, materials, and automation.
• Own processes for laser cutting, probe stitching, alignment, and mechanical integration.
• Oversee SMT assembly and vertical probe card manufacturing flows, ensuring DFM and scalability.
• Lead root‑cause analysis for yield excursions and reliability failures, implement 8D/4C, and drive automation.

Skills

Leadership

Process Engineering

Statistical analysis

Problem solving

Cross‑Functional Collaboration

Change Management

Communication

Manufacturing operations

DFM

DOE

Education

Bachelor’s degree in Engineering

Master’s degree in Engineering

PhD (related field)

Tools

MES systems

Digital twins

Factory automation

Job description

FormFactor, Inc. is launching a large‑scale startup operation in Farmers Branch, TX and seeks a Sr Manager of Process Engineering to lead all process development, optimization, and sustaining activities across a vertically integrated probe card manufacturing operation.

You will drive continuous improvement, develop a technology roadmap, and guide teams in fab processes, probe stitching, SMT, and vertical probe card assembly to meet performance and cost targets.