Sr. Staff Integration Engineer
Job Description
The Sr. Staff Integration Engineer is responsible for defining, optimizing, and sustaining 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.
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 Groups
- Cross-Functional Work
- Data Analysis
- Defect Metrology
- Defect Reduction
- Defects Analysis
- Design for Manufacturing (DFM)
- Design for Reliability (DFR)
- Design of Experiments (DOE)
- DMAIC
- DMAIC Process Improvement
- Electrical Failure Analysis
- Electrical Validation
- Electroplating
- Etching
- Failure Analysis
- Manufacturing Execution Systems (MES)
- Manufacturing Scale-Up
- ME
- Microelectromechanical Systems (MEMS)
- New Product Introduction (NPI)
Education & Experience
- 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
Pay Range
This role in Livermore, California pays between $163,400.00 and $214,410.00 per year, depending on your experience, skills, and background. Pay may vary in other locations.
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.