Process Engineer

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: 

1) 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.  

2) 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).  

3) 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.  

4) 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).  

5) 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.  

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.