Sr. Staff Integration Engineer

FormFactor, Inc.; Ulmar (CA); On-site; USD 163,400 - 214,410; Full time

Job summary

FormFactor, Inc. is seeking a Sr. Staff Integration Engineer to define, optimize, and sustain end-to-end process integration flows for probe card manufacturing in a high-volume semiconductor environment.

You will lead cross-functional teams spanning wafer fabrication, MEMS, assembly, interconnect, and electrical test to drive yield, manufacturability, and scalability with autonomy. The role emphasizes cross-site technology transfer, NPI readiness, and robust change control, while mentoring

Qualifications

• 8D Report, Change Management, Cross-Functional Work, Data Analysis, Defect Metrology, Defect Reduction, Design for Manufacturing (DFM), Design for Reliability (DFR), Design of Experiments (DOE), DMAIC, Electrical Failure Analysis, Electroplating, Etching, Manufacturing Execution Systems (MES), MEMS, New Product Introduction (NPI)

Responsibilities

• Define, own, and continuously improve end-to-end process integration flows for probe card manufacturing
• Ensure alignment of unit process performance to product-level electrical, mechanical, and reliability targets
• Identify and manage integration risks, interactions, and trade-offs across modules
• Lead integration-level yield improvement initiatives using data-driven analysis and structured problem solving
• Investigate complex yield excursions, defect mechanisms, and cross-process interactions
• Drive defect reduction, process capability improvements, and cycle time reduction
• Lead integration activities for NPI, pilot builds, and ramp to high-volume manufacturing
• Own integration readiness criteria including process stability, control plans, and manufacturability
• Support cross-site technology transfer and process replication with strong change control discipline
• Develop and maintain integrated process flows, specifications, and control strategies
• Define critical process parameters, control points, and monitoring strategies (SPC/FDC)
• Ensure robust process window characterization and documentation
• Act as the technical integration interface across Process, Equipment, Product, Yield, Quality, and Manufacturing teams
• Influence design for manufacturability (DfM) and design for reliability (DfR)
• Partner with operations on process stability, tool readiness, and production performance
• Analyze inline, electrical test, metrology, and defect data to identify integration gaps
• Design and execute complex DOEs to resolve multi-variable process interactions
• Utilize structured methodologies (DMAIC, 8D) for root cause analysis
• Evaluate, approve, and implement changes to processes, materials, equipment, and flows
• Ensure compliance with change control processes, qualification standards, and documentation requirements
• Maintain traceability and configuration control across process changes
• Mentor and guide junior and senior engineers on integration practices and problem solving
• Provide technical leadership on cross-functional and multi-site initiatives
• Influence long-term integration strategy and technology roadmap
• Share knowledge and foster problem-solving culture across teams

Skills

8D Report

Change Management

Cross-Functional Work

Data Analysis

Defect Metrology

Defect Reduction

DFM

DFR

DOE

DMAIC

Electrical Failure Analysis

Electroplating

Etching

MES

MEMS

NPI

Education

Bachelor’s degree

Master’s degree

PhD

Job description

Job Title: Sr. Staff Integration Engineer

FormFactor, Inc. (NASDAQ: FORM) is a leading provider of test and measurement technologies essential to the semiconductor product life cycle. This role supports the company's mission by enhancing device performance and yield knowledge for its global customers.

Shift

Day shift.

Job Description

The Sr. Staff Integration Engineer defines, optimizes, and sustains end-to-end process integration flows for probe card manufacturing in a high‑volume semiconductor environment. This senior technical authority integrates complex unit processes across wafer‑level fabrication, MEMS, precision assembly, interconnect, and electrical test. The position drives yield performance, manufacturability, and scalability by aligning cross‑functional engineering, operations, and product teams. It operates with significant autonomy, leading problem‑solving, technology transfer, and continuous improvement initiatives, mentoring engineers and influencing integration strategy across sites. The role acts as the primary technical interface between process modules, ensuring integrated process flows meet product, quality, and reliability requirements.

Key Responsibilities

Process Integration Ownership

• Define, own, and continuously improve end-to-end process integration flows for probe card manufacturing
• Ensure alignment of unit process performance to product-level electrical, mechanical, and reliability targets
• Identify and manage integration risks, interactions, and trade‑offs across modules

Yield & Performance Optimization

• Lead integration-level yield improvement initiatives using data‑driven analysis and structured problem solving
• Investigate complex yield excursions, defect mechanisms, and cross‑process interactions
• Drive defect reduction, process capability improvements, and cycle time reduction

New Product Introduction (NPI) & Technology Transfer

• Lead integration activities for NPI, pilot builds, and ramp to high-volume manufacturing
• Own integration readiness criteria including process stability, control plans, and manufacturability
• Support cross-site technology transfer and process replication with strong change control discipline

Process Flow Development & Control

• Develop and maintain integrated process flows, specifications, and control strategies
• Define critical process parameters, control points, and monitoring strategies (SPC/FDC)
• Ensure robust process window characterization and documentation

Cross-Functional Technical Leadership

• Act as the technical integration interface across Process, Equipment, Product, Yield, Quality, and Manufacturing teams
• Influence design for manufacturability (DfM) and design for reliability (DfR)
• Partner with operations on process stability, tool readiness, and production performance

Data Analysis & Problem Solving

• Analyze inline, electrical test, metrology, and defect data to identify integration gaps
• Design and execute complex DOEs to resolve multi‑variable process interactions
• Utilize structured methodologies (DMAIC, 8D) for root cause analysis

Change Management & Governance

• Evaluate, approve, and implement changes to processes, materials, equipment, and flows
• Ensure compliance with change control processes, qualification standards, and documentation requirements
• Maintain traceability and configuration control across process changes

Mentorship & Technical Influence

• Mentor and guide junior and senior engineers on integration practices and problem solving
• Provide technical leadership on cross-functional and multi-site initiatives
• Influence long-term integration strategy and technology roadmap

Skills

8D Report, Change Management, Cross-Functional Work, Data Analysis, Defect Metrology, Defect Reduction, Design for Manufacturing (DFM), Design for Reliability (DFR), Design of Experiments (DOE), DMAIC, Electrical Failure Analysis, Electroplating, Etching, Manufacturing Execution Systems (MES), MEMS, New Product Introduction (NPI)

Education & Experience

Minimum of 12 years related experience with a Bachelor’s degree; 8 years with a Master’s; 5 years with a PhD; or equivalent experience.

Pay Range

$163,400.00 - $214,410.00 per year in Livermore, California. Pay may vary in other locations.

Benefits

Full benefits package including medical, dental, vision, life insurance, disability coverage, 401(k) with company match, employee stock purchase plan (ESPP), paid time off, quarterly profit‑sharing bonuses, and 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 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.

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