Sr Process Development Engineer

FormFactor, Inc.; Livermore (CA); On-site; USD 91,000 - 119,000; Full time

Benefits offered by this job

Medical

Dental

Vision

Life insurance

Disability coverage

401(k) with company match

ESPP

Paid time off

Profit-sharing bonuses

Flexible spending accounts

Job summary

FormFactor, Inc. in Livermore, California seeks a hands‑on engineer to advance process and technology development for new product initiatives in manufacturing environments.

You will design and execute experiments, evaluate materials and methods, and help scale processes from R&D to production with an eye toward cost, quality, reliability, and schedule. Collaborating with cross‑functional teams, you will lead transfer activities, provide training, and deliver technical documentation, risk

Qualifications

• Bachelor's degree and 2+ years related experience or advanced degree.
• Experience with statistical techniques, DOE, SPC, and process capability tools.
• Proven ability to troubleshoot manufacturing or development challenges.

Responsibilities

• Develop, evaluate, and implement new manufacturing processes, materials, and technologies.
• Design and execute DOE studies and analyze results.
• Lead transfer of processes from R&D to manufacturing and support NPI activities.
• Prepare technical reports, risk assessments, and engineering recommendations.
• Collaborate with cross‑functional teams to meet cost, quality, reliability and schedule goals.

Skills

DOE

SPC

Python

Excel

Statistical Analysis

Design of Experiments

Quality Improvement

AutoCAD

Education

Bachelor's degree

Tools

AutoCAD

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

Key Responsibilities

Process & Technology Development

• Develop, evaluate, and implement new manufacturing processes, materials, and technologies to support new product initiatives.
• Conduct technology assessments and feasibility studies for next-generation products and manufacturing methods.
• Design and execute process development plans to transition concepts from laboratory and pilot phases into production-ready solutions.
• Perform hands‑on engineering work to establish, optimize, and sustain new and existing manufacturing processes.

Experimental Design & Characterization

• Design, execute, and analyze experiments utilizing Design of Experiments (DOE) methodologies.
• Characterize products, materials, equipment, and process outputs to verify performance against customer and engineering requirements.
• Utilize statistical analysis techniques, process capability studies, and Statistical Process Control (SPC) methods to evaluate process performance.
• Analyze process data to identify trends, root causes, and opportunities for improvement.

New Product Introduction (NPI)

• Support New Product Introduction (NPI) activities from concept development through manufacturing release.
• Collaborate with cross‑functional teams to develop scalable manufacturing solutions that meet cost, quality, reliability, and schedule objectives.
• Assist in product and process qualification activities, including validation testing and process capability assessments.
• Support pilot builds and manufacturing readiness activities for new products.

Process Transfer & Manufacturing Support

• Lead and support the transfer of new processes and technologies from R&D into manufacturing environments.
• Create and maintain work instructions, process flows, specifications, training materials, and supporting documentation.
• Provide training and cross‑functional knowledge transfer to manufacturing teams.
• Troubleshoot process‑related issues and implement corrective and preventive actions to improve process stability and performance.

Equipment & Supplier Collaboration

• Develop and integrate new manufacturing process modules and equipment into existing production platforms.
• Support development of specialized assembly processes, including adhesive and epoxy dispensing applications.
• Work closely with equipment vendors, suppliers, and fabricators to source, evaluate, and improve materials and tooling solutions.
• Participate in equipment selections, qualifications, and acceptance activities.

Continuous Improvement & Project Support

• Identify and implement process improvements that enhance yield, quality, throughput, reliability, and cost performance.
• Lead or support process development projects of moderate scope and complexity.
• Prepare technical reports, presentations, risk assessments, and engineering recommendations.
• Collaborate with Manufacturing, Quality, Supply Chain, Product Engineering, and R&D teams to drive successful project outcomes.

Preferred Qualifications & Experiences

• Bachelor's degree in Mechanical Engineering, Materials Science, Chemical Engineering, Manufacturing Engineering, or a related engineering discipline.
• Engineering experience in process development, manufacturing engineering, product development, or a related technical field.
• Experience utilizing statistical analysis techniques, DOE methodologies, SPC, and process capability tools.
• Strong analytical and problem‑solving skills with demonstrated experience troubleshooting complex manufacturing or development challenges.
• Ability to work effectively in cross‑functional environments and manage multiple priorities.
• Cross‑disciplinary education or experience spanning materials, manufacturing processes, equipment, and product development.
• Hands‑on experience developing and scaling manufacturing processes from R&D through production.
• Demonstrated track record of successfully transferring processes from R&D into manufacturing.
• Experience supporting semiconductor, electronics, advanced materials, MEMS, precision manufacturing, or related industries.
• Experience developing adhesive, dispensing, assembly, packaging, or automation processes.
• Knowledge of process qualification methodologies, risk assessments, PFMEA, and change control practices.
• Proficiency with JMP, Minitab, Python, Excel, or similar engineering data analysis tools.

Skills

• Autodesk AutoCAD
• Autodesk AutoCAD
• Design of Experiments (DOE)
• Engineering Materials
• Failure Analysis
• Hands‑On Learning
• Learning Quickly
• Materials Engineering
• Mechanical Equipments
• Metrology
• New Process Development
• New Process Implementation
• New Product Introduction (NPI)
• Process Capability
• Process Development (PD)
• Process Improvement Projects
• Process Improvements
• Process Transfers
• Product Process Development
• Quality Improvement Processes
• SolidWorks
• Statistical Data
• Statistical Process Control (SPC)
• Statistical Process Control (SPC) Charts
• Transfer of Training

Education & Experience

Bachelor’s degree and a minimum of 2 years of related experience; or an advanced degree without experience; or equivalent work experience|

Required Pay Range

$90,500.00 - $118,755.00

Pay Range Explained

This role in Livermore, California pays between $90,500.00 and $118,755.00 per year, depending on your experience, skills, and background. Pay may vary in other locations.

Benefits

• medical
• dental
• vision
• life insurance
• disability coverage
• a 401(k) with company match
• employee stock purchase plan (ESPP)
• paid time off
• quarterly profit‑sharing bonuses
• 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.

Remote Eligibility

For roles that are designated as remote‑eligible, employees cannot be located in:AL, AK, AR, DE, GA, HI, IL, IA, 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.

Our Mission

We enable our customers to revolutionize semiconductors with advanced packaging bringing tomorrow's electronics to life.

Our Values

Our values were collaboratively created to reflect the essence of who we are as a company and as a team of people. The values are created for us, by us. Our people designed the FORM acronym and imagery as a constant reminder to live these values daily. Together, we embrace these guiding principles, fostering a positive and united environment for all. Focus on the Customer Ownership & Accountability Respectfully & Effectively Communicate Motivate & Develop People

Learn more by visiting HERE.