Sr Staff Integration Engineer

About the Role

FormFactor, Inc. (NASDAQ: FORM) is a leading provider of essential test and measurement technologies along the full semiconductor product life cycle. 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 role serves as a senior technical authority, integrating 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, while mentoring engineers and influencing integration strategy across sites.

Responsibilities

• Assembly & Test Integration Leadership
  • Own integration strategy across all Assembly & Test operations including solder paste printing, surface mount technology (SMT), pick-and-place assembly, reflow soldering, PCB assembly, underfill and adhesive processes, mechanical assembly, alignment and calibration, electrical verification, and final product test.
  • Define process windows, acceptance criteria, and control plans for critical assembly operations.
  • Lead optimization of solder joint reliability, component placement accuracy, reflow profiles, coplanarity, and assembly yield.
  • Drive integration improvements between PCB design, assembly processes, probe structures, and final electrical performance.
  • Develop assembly flow architectures that support volume scalability, cycle-time reduction, and manufacturability.
  • Partner with contract manufacturers and internal assembly operations to ensure process consistency and technology transfer success.
  • Analyze assembly-related yield losses including solder defects, placement errors, opens, shorts, warpage, misalignment, and handling damage.
  • Establish qualification methodologies for assembly materials, solder alloys, adhesives, PCB technologies, and new assembly equipment.
• 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.
• 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.
• 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.

Requirements

• Minimum of 12 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 experience.

Skills

• Assembly Manufacturing
• Assembly Operations
• Assembly Testing
• Probe Cards
• Process Integration
• Process Operations
• Product Integration
• Semiconductor Device Fabrication
• Semiconductor Fabrication
• Semiconductor Industry
• Semiconductor Manufacturing

Schedule

Regular day shift hours.

Benefits

• Medical, dental, and vision insurance
• Employee Assistance Program (EAP)
• Short-term and long-term disability
• Life insurance
• Flexible spending and savings accounts
• 401(k) retirement plan
• Employee Stock Purchase Plan (ESPP)
• Paid time off

Location: Farmers Branch, TX. This role is not eligible for remote work in the following states: 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.