Process Engineer

Job Description

The Process Engineer, Assembly & Test owns and optimizes assembly and electrical test equipment, used in the manufacturing of high-performing probe cards, to ensure safety, quality, and delivery (SQD) targets. Drive uptime, yield, and throughput by applying structured troubleshooting, preventive/predictive maintenance, and data-driven continuous improvement aligned with FormFactor processes.

Key Responsibilities

• Process Ownership & Reliability

• Serve as process owner for assigned assembly/test tools (e.g., precision alignment stations, adhesives/epoxy dispense, curing ovens, bonders, electrical test stands/handlers and laser cutting).
• Author and update standard work (setup, qualification, operation) and maintenance work instructions.

• Troubleshooting & Root Cause Analysis

• Apply 5 Whys, Ishikawa, pareto analysis, and fault isolation to resolve equipment, fixture, sensor, and software PLC/HMI issues.
• Execute containment and implement corrective/preventive actions (CAPA); verify effectiveness via run charts and capability checks (e.g., Cpk, GR&R for measurement systems).

• Process Support & Continuous Improvement

• Partner with Equipment Engineering to ensure equipment meets process windows (adhesive deposition, cure profiles, alignment tolerances, electrical test limits).
• Propose and implement low-cost automation, poke-yoke fixtures, recipe optimizations, and error-proofing.
• Participate in DOE and qualification (IQ/OQ/PQ) for equipment changes, capture learnings in the equipment history log.

• Data & Documentation

• Track uptime, yield loss by cause, first-pass yield (FPY), cycle time, and throughput; publish weekly dashboards.
• Maintain calibration certificates, change control records, and risk assessments (PFMEA updates for equipment changes).

• Safety, Compliance & Training

• Ensure equipment complies with EHS (LOTO, machine guarding, ergonomics, chemical handling for adhesives/solvents).
• Train operators/technicians on safe operations, preventive checks, and basic troubleshooting; verify training effectiveness with observations and signoffs.

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

• Computerized Maintenance Management Systems (CMMS)
• Electrical Testing Equipments
• ESD Control
• HMI Software
• IQ OQ PQ
• Measurement Systems Analysis (MSA)
• Metal Bonding
• Metrology
• Precision Alignments
• Process Failure Mode Effects Analysis (PFMEA)
• Python (Programming Language)
• Reading Schematics
• Robotics
• SPC Charts
• Structured Query Language (SQL)
• Vendor Management

Education & Experience

• Bachelor’s degree and a minimum of 2 years of related experience; or an advanced degree without 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.