Sr. Principal Assembly & Test Engineer – SMT (Surface Mount Technology), Probe Card Manufacturing

FormFactor Inc.; Farmers Branch (TX); On-site; USD 90,000 - 120,000; Full time

Job summary

FormFactor Inc. in Farmers Branch, Texas, is seeking a Sr. Principal Assembly & Test SMT Engineer to own and optimize Surface Mount Technology processes for probe card manufacturing. The candidate will provide technical leadership and ensure high-quality PCB assembly while supporting cross-functional teams.

Ideal applicants should possess a Bachelor’s degree in a relevant field with 3–7 years of experience in SMT or PCB assembly. The role emphasizes communication, troubleshooting, and continuous improvement skills.

Qualifications

• Bachelor’s degree in related field required.
• 3–7 years of SMT or PCB assembly experience preferred.
• Lean/6σ Green Belt or Black Belt certification desirable.

Responsibilities

• Own and optimize Surface Mount Technology processes.
• Provide engineering support for SMT equipment.
• Lead Lean/6σ initiatives to enhance process robustness.

Skills

Communication

Continuous Improvement

Cross-Functional Teamwork

Operational Excellence

Structured Problem Solving

Troubleshooting

Education

Bachelor’s degree in Electrical Engineering or related field

Tools

SPI (Solder Paste Inspection)

Pickandplace machine

Reflow oven

Job description

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

The Sr. Principal Assembly & Test (A&T) SMT Engineer is responsible for owning, optimizing, and supporting Surface Mount Technology processes used in probe card manufacturing. This role ensures high quality PCB assembly, stable process capability, and predictable output across pickandplace, reflow, inspection, and associated upstream/downstream steps. The engineer provides technical leadership for SMT line performance, defect reduction, equipment improvements, and cross functional integration with plating, lithography, mechanical assembly, and electrical test teams.

Key Responsibilities

SMT Process Engineering

• Develop, qualify, and maintain SMT processes, solder paste selection, solder paste injection and inspection, reflow profiling, and placement parameters.
• Own recipe creation and optimization for high density advanced probe card PCBs.
• Drive process capability improvements (Cp/Cpk) and ensure stable production performance.

Equipment Ownership

• Provide daily engineering support for SMT equipment such as:
• Stencil printer
• Pickandplace machine
• Reflow oven
• SPI (Solder Paste Inspection)
• Lead troubleshooting and root cause analysis for equipment failures, misplacements, reflow defects, or inspection inaccuracies.
• Define and maintain PM schedules, calibration, and spare parts strategies.

Quality & Yield Improvement

• Monitor and analyze yield, defect Paretos, and SPC trends to identify systemic issues.
• Lead DfX (Design for Assembly, Design for Manufacturability) discussions with design engineering.
• Implement corrective actions and sustainable process controls for solder bridging, opens, voiding, tombstoning, and wetting failures.

Manufacturing Support

• Support production technicians with process deviations, equipment issues, and new product introductions.
• Develop documentation including WI/SOPs, process parameters, machine setup sheets, and inspection criteria.
• Drive cycle time reduction, throughput improvements, and operator training.

Cross Functional Collaboration

• Work closely with:
• Plating & Metallization Engineers
• Photolithography Engineers
• Mechanical/Assembly Engineering
• Electrical Test Engineering (FPT, PRVX4)
• Supply Chain & Quality
• Provide engineering support during prototype builds and customer specific configurations.

Continuous Improvement

• Lead Lean/6σ initiatives to reduce waste, improve flow, and enhance process robustness.
• Evaluate and introduce new materials (solder paste, adhesives, fluxes) and improved stencil/hardware designs.
• Participate in equipment justification and capital project planning.

Preferred Experiences And Backgrounds

• Bachelor’s degree in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, or related field.
• 3–7 years of SMT or PCB assembly experience (semiconductor, PCBA, or electronics assembly preferred).
• Strong understanding of solder paste behavior, reflow principles, component placement strategies, and defect mechanisms.
• Hands‑on experience with SMT equipment and inspection systems (SPI, AOI).
• Proficiency with SPC, FMEA, DOE, and root cause problem solving.
• Experience in probe card, semiconductor test hardware, or high precision PCB manufacturing.
• Familiarity with high density BGAs, fine pitch components, and micro assembly.
• Knowledge of CAM/EDA data for stencil/paste aperture optimization.
• Lean/6σ Green Belt or Black Belt certification.
• Experience with MES systems and factory automation.

Skills

Communication, Continuous Improvement, Cross-Functional Teamwork, Manufacturing Support, Operational Excellence, Structured Problem Solving, Taking Ownership, Troubleshooting, Working in a Fast-Paced Environment, Writing Documentation.

Education & Experience

Minimum of 8 years of related experience with a Bachelor’s degree; or 6 years and a Master’s degree; or a PhD with 3 years experience; or equivalent 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.