Sr Manager, Process Engineering

FormFactor, Inc.; Farmers Branch (TX); On-site; USD 140,000 - 210,000; Full time

Benefits offered by this job

Medical

Dental

Vision

EAP

Disability insurance

Life insurance

Flex spending accounts

401(k)

ESPP

Paid time off

Job summary

FormFactor, Inc. is seeking a Sr Manager, Process Engineering in Farmers Branch to lead process development across fab processes, probe assembly, SMT operations, and new product introduction.

You will develop and execute the technology roadmap, drive continuous improvement, and partner with R&D, Operations, and Quality to meet customer requirements. The role requires a track record of 10+ years in semiconductor manufacturing, strong leadership, and hands‑on capability in process controls,

Qualifications

• 10+ years in semiconductor/manufacturing leadership.
• Bachelor’s or Master’s in Engineering.
• Experience with probe card manufacturing, MEMS, or related high‑precision processes.
• Strong leadership, communication, and cross‑functional collaboration.

Responsibilities

• Lead and develop a high‑performing Process Engineering organization covering fab, probe assembly, SMT, and NPI.
• Define the long‑term process technology roadmap aligned with R&D, Operations, and Quality.
• Drive talent development through growth plans, training, and succession planning.
• Establish metrics (yield, Cp/Cpk, cycle time, OEE) and drive continuous improvement.
• Partner with Manufacturing to own output, yield, and cost targets.
• Oversee processes such as thin‑film deposition, lithography, etch, metallization, planarization, cleaning, and metrology.
• Lead qualification and integration of new fab equipment, chemistries, and automation.
• Own processes for laser cutting, probe stitching, alignment, and mechanical integration.

Skills

Process Engineering

Leadership

Semiconductor

DOE

Statistical Analysis

Automation

Project Management

Quality Systems

Lean Manufacturing

Mentoring

Education

Bachelor’s or Master’s in Engineering

Tools

MES systems

Digital twins

Job description

Job Description

FormFactor is launching a large‑scale, high‑impact startup operation in Farmers Branch—an exciting opportunity to help build, define, and lead a cutting‑edge manufacturing environment from the ground up. As part of a collaborative and people‑centered culture, you will shape both the technology and the team that powers our next phase of growth. The Sr Manager, Process Engineering is responsible for leading all process development, optimization, and sustaining engineering activities across a vertically integrated probe card manufacturing operation. This role oversees engineering teams supporting semiconductor‑style fab processes, probe stitching, and SMT‑based vertical probe card assembly, ensuring world‑class manufacturing capability, operational efficiency, and product performance. The Sr Manager will drive continuous improvement, yield enhancement, equipment strategy, and technology roadmap execution to support customer requirements and business growth.

Key Responsibilities

• Lead and develop a high‑performing Process Engineering organization covering fab processes, probe assembly, SMT operations, and new product introduction (NPI).
• Define the long‑term process technology roadmap aligned with R&D, Operations, and Quality.
• Drive talent development through individualized growth plans, skill‑building, cross‑training and succession planning.
• Establish engineering performance metrics (yield, Cp/Cpk, cycle time, OEE, defectivity) and drive continuous improvement.
• Partner with Manufacturing Operations to jointly own output, yield, and cost targets.
• Oversee processes such as thin‑film deposition, lithography, etch, metallization, planarization, cleaning, and metrology. Ensure robust process controls (SPC, DOE, FMEA) and maintain high‑yield, stable wafer‑type production flows.
• Lead qualification and integration of new fab equipment, chemistries, materials, and automation.
• Own all processes related to laser cutting, probe stitching, alignment, and mechanical integration. Develop breakthrough process capabilities to improve probe coplanarity, electrical performance, and mechanical reliability.
• Oversee SMT assembly processes, including solder paste deposition, component placement, reflow, AOI, underfill, etc. Develop and optimize assembly flows for vertical probe cards, integrating substrates, MEMS structures, interposers, connectors, and mechanical fixtures.
• Ensure DFM standards and process scalability for new card architectures.
• Lead root‑cause analysis for yield excursions, field returns, and reliability failures. Implement structured problem‑solving frameworks (8D, 4C).
• Drive automation, SPC dashboards, digital manufacturing systems, and advanced analytics into process control.
• Partner with R&D to industrialize new probe card technologies, ensuring manufacturability and cost competitiveness.
• Work with Supply Chain on material qualification, vendor capability, and risk mitigation.
• Collaborate with Quality Engineering to ensure compliance with industry standards and customer specifications.
• Ensure all processes meet EHS, chemical handling, and equipment safety requirements.
• Maintain robust documentation for processes, change control, FMEA, control plans, and work instructions.
• Lead process audits and customer technical reviews.

Preferred Experiences & 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, advanced packaging, 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 technical depth combined with practical manufacturing intuition.
• Excellent communication and ability to influence at both engineering and executive levels.
• Strategic thinker with hands‑on capability to troubleshoot the most complex process challenges.
• Passion for team development, innovation, and continuous improvement.

Benefits

• Medical
• Dental
• Vision
• EAP
• Short‑term and long‑term disability
• Life insurance
• Flexible spending and savings accounts
• 401(k)
• ESPP
• Paid time off

Skills

• Change Management
• Cleanroom Operations
• Communication
• Conflict Resolution
• Continuous Improvement
• Cross‑Functional Collaboration
• Decision Making
• Design of Experiments (DOE)
• Equipment Qualification
• Failure Analysis
• Lean Manufacturing
• Manufacturing Operations
• Materials Characterization
• Mentor Coaching
• Metrology
• Microfabrication
• People Leadership
• Performance Management (PM)
• Problem Solving
• Process Engineering
• Process Integration
• Project Management
• Quality Management Systems (QMS)

Education & Experience

Minimum of 10 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 work experience.

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. For roles that are designated as remote‑eligible, employees cannot be located in: AL, AK, AR, DE, GA, HI, IL, IA, KY, LA, ME, MD, MS, MO, NE, NV, NJ, NM, ND, OK, PA, RI, SC, SD, TN, WV, WI, WY. This list is continuously evolving and being updated, please check back with us if the state you live in is on the exclusion list. A role is remote‑eligible only when it is listed as "Remote" in the job location.