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:
FormFactor is launching a large‑scale, high‑impact startup operation in Farmers Branch—an exciting opportunity to help build, define, and lead a cutting‑edge manufacturing environment from the ground up. As part of a collaborative and people‑centered culture, you will shape both the technology and the team that powers our next phase of growth.
The Sr Manager, Process Engineering is responsible for leading all process development, optimization, and sustaining engineering activities across a vertically integrated probe card manufacturing operation. This role oversees engineering teams supporting semiconductor‑style fab processes, probe stitching, and SMT‑based vertical probe card assembly, ensuring world‑class manufacturing capability, operational efficiency, and product performance. The Sr Manager will drive continuous improvement, yield enhancement, equipment strategy, and technology roadmap execution to support customer requirements and business growth.
Key Responsibilities:
Leadership & Strategy
Lead and develop a high‑performing Process Engineering organization covering fab processes, probe assembly, SMT operations, and new product introduction (NPI).
Define the long‑term process technology roadmap aligned with R&D, Operations, and Quality.
Drive talent development through individualized growth plans, skill-building, cross-training and succession planning.
Establish engineering performance metrics (yield, Cp/Cpk, cycle time, OEE, defectivity) and drive continuous improvement.
Partner with Manufacturing Operations to jointly own output, yield, and cost targets.
Semiconductor‑Style Fab Process Ownership
Oversee processes such as thin‑film deposition, lithography, etch, metallization, planarization, cleaning, and metrology.
Ensure robust process controls (SPC, DOE, FMEA) and maintain high‑yield, stable wafer‑type production flows.
Lead qualification and integration of new fab equipment, chemistries, materials, and automation.
Probe Stitching & Micro‑Assembly
Own all processes related to laser cutting, probe stitching, alignment, and mechanical integration.
Develop breakthrough process capabilities to improve probe coplanarity, electrical performance, and mechanical reliability.
SMT & Vertical Probe Card Manufacturing
Oversee SMT assembly processes, including solder paste deposition, component placement, reflow, AOI, underfill, etc.
Develop and optimize assembly flows for vertical probe cards, integrating substrates, MEMS structures, interposers, connectors, and mechanical fixtures.
Ensure DFM standards and process scalability for new card architectures.
Continuous Improvement & Operational Excellence
Lead root‑cause analysis for yield excursions, field returns, and reliability failures.
Implement structured problem‑solving frameworks (8D, 4C).
Drive automation, SPC dashboards, digital manufacturing systems, and advanced analytics into process control.
Cross‑Functional Collaboration
Partner with R&D to industrialize new probe card technologies, ensuring manufacturability and cost competitiveness.
Work with Supply Chain on material qualification, vendor capability, and risk mitigation.
Collaborate with Quality Engineering to ensure compliance with industry standards and customer specifications.
Compliance, Safety & Documentation
Ensure all processes meet EHS, chemical handling, and equipment safety requirements.
Maintain robust documentation for processes, change control, FMEA, control plans, and work instructions.
Lead process audits and customer technical reviews.
Preferred Experiences & Qualifications:
Bachelor’s or Master’s degree in Engineering (Mechanical, Electrical, Materials, Chemical, or related).
10+ years of experience in semiconductor manufacturing, probe card manufacturing, advanced packaging, MEMS, or similar high‑precision industries.
Proven leadership experience managing engineering or technical teams.
Deep expertise in process engineering, statistical analysis, and advanced problem‑solving.
Experience in probe card manufacturing, MEMS probe technologies, or advanced micro‑assembly.
Familiarity with SMT, micro‑joining, precision alignment technologies, and optical metrology.
Understanding of reliability testing, thermal‑mechanical modeling, and electrical test correlation.
Experience with factory automation, MES systems, and digital twins
Strong technical depth combined with practical manufacturing intuition.
Excellent communication and ability to influence at both engineering and executive levels.
Strategic thinker with hands‑on capability to troubleshoot the most complex process challenges.
Passion for team development, innovation, and continuous improvement.
Farmers Branch, TX
Benefits offered for this role include medical, dental, vision, EAP, short-term and long-term disability, life insurance, flexible spending and savings accounts, 401(k), ESPP and paid time off.
Skills:
Change Management, Change Management, Cleanroom Operations, Communication, Conflict Resolution, Continuous Improvement, Cross-Functional Collaboration, Decision Making, Design of Experiments (DOE), Equipment Qualification, Failure Analysis, Leadership Training and Development, Lean Manufacturing, Manufacturing Operations, Materials Characterization, Mentor Coaching, Metrology, Microfabrication, People Leadership, Performance Management (PM), Problem Solving, Process Engineering, Process Integration, Project Management, Quality Management Systems (QMS) {+ 9 more}Education & Experience:
Minimum of 10 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 work experience | RequiredEqual 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.
Skills Required
- Bachelor's degree in Engineering (Mechanical, Electrical, Materials, Chemical) or higher
- Minimum of 10+ years related experience (or 8 years with Master's, 5 years with PhD) in relevant industries
- Proven leadership experience managing engineering or technical teams
- Deep expertise in process engineering, statistical analysis, and advanced problem solving (SPC, DOE, FMEA)
- Experience in probe card manufacturing, MEMS probe technologies, or advanced micro-assembly
- Familiarity with SMT assembly processes (solder paste deposition, component placement, reflow, AOI), micro-joining, precision alignment, and optical metrology
- Understanding of reliability testing, thermal-mechanical modeling, and electrical test correlation
- Experience with factory automation, MES systems, and digital twins
- Experience driving continuous improvement, root-cause analysis (8D, 4C), and manufacturing metrics (yield, Cp/Cpk, OEE)
- Strong communication and ability to influence at engineering and executive levels; talent development experience
What We Do
FormFactor, Inc. is a leading provider of essential test and measurement technologies for the semiconductor industry, offering products like probe cards, analytical probes, and cryogenic systems to support the full integrated circuit (IC) life cycle.
