FormFactor Inc. · 9 hours ago
Director, Process Engineering
Farmers Branch, TX
Full-time
Onsite
Director/Executive
10+ years expFormFactor Inc. is a leading provider of essential test and measurement technologies for the semiconductor industry. They are seeking a Director of Process Engineering to lead process development and optimization activities in a new manufacturing operation, ensuring operational efficiency and product performance.
ManufacturingMobileSemiconductor
Responsibilities
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
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
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
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
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
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
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
Qualification
Required
Minimum of 12+ years of relevant experience in leadership roles, with a Bachelor's degree; or 10 years and a Master's degree; or a PhD with 8 years experience; or equivalent experience
Preferred
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
Benefits
Medical
Dental
Vision
EAP
Short-term and long-term disability
Life insurance
Flexible spending and savings accounts
401(k)
ESPP
Paid time off
Company
FormFactor Inc.
FormFactor is a leading provider of essential test and measurement technologies along the full IC life cycle – from characterization, modeling, reliability, and design debug, to qualification and production test.
1001-5000 employees
H1B Sponsorship
FormFactor Inc. has a track record of offering H1B sponsorships. Please note that this does not
guarantee sponsorship for this specific role. Below presents additional info for your
reference. (Data Powered by US Department of Labor)
Distribution of Different Job Fields Receiving Sponsorship
Represents job field similar to this job
Trends of Total Sponsorships
2025 (28)
2024 (20)
2023 (28)
2022 (32)
2021 (21)
2020 (27)
Funding
Current Stage
Public CompanyTotal Funding
$15M2025-01-07Post Ipo Equity· $15M
2003-06-12IPO
Leadership Team
Mike Slessor
Chief Executive Officer
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