Sr Manager, Process Engineering

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

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.

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
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.
  

Semiconductor‑Style Fab Process Ownership

• 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.
  

Probe Stitching & Micro‑Assembly

• 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.
  

SMT & Vertical Probe Card Manufacturing

• 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.
  

Continuous Improvement & Operational Excellence

• 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.
  

Cross‑Functional Collaboration

• 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.
  

Compliance, Safety & Documentation

• 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.
  

Farmers Branch, TX
Benefits offered for this role include medical, dental, vision, EAP, short-term and long-term disability, life insurance, flexible spending and savings accounts, 401(k), ESPP and paid time off.
Skills
Change Management, Change Management, Cleanroom Operations, Communication, Conflict Resolution, Continuous Improvement, Cross-Functional Collaboration, Decision Making, Design of Experiments (DOE), Equipment Qualification, Failure Analysis, Leadership Training and Development, 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) {+ 9 more}
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| Required
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.