{"schemaVersion":"jobsearcher.job.v1","id":"128c5b1d6a1bc4e90a56712a","url":"https://jobsearcher.com/jobs/128c5b1d6a1bc4e90a56712a","canonicalUrl":"https://jobsearcher.com/jobs/128c5b1d6a1bc4e90a56712a","title":"Sr Principal Process Development Engineer","description":"Forming Our Future together\n\nFormFactor, 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.\n\nRooted 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.\n\nShift:\n\nThe regular hours for this position are day shift.\n\nJob Description:\n\nThe Sr Principal Process Development Engineer is responsible for owning, optimizing, and supporting Surface Mount Technology processes used in probe card manufacturing. This role ensures high‑quality PCB assembly, stable process capability, and predictable output across pick‑and‑place, reflow, inspection, and associated upstream/downstream steps. The engineer provides technical leadership for SMT line performance, defect reduction, equipment improvements, and cross‑functional integration with plating, lithography, mechanical assembly, and electrical test teams.\n\nKey Responsibilities:\n\nSMT Process Engineering\n\nDevelop, qualify, and maintain SMT processes, solder paste selection, solder paste injection and inspection, reflow profiling, and placement parameters.\n\nOwn recipe creation and optimization for high‑density advanced probe card PCBs.\n\nDrive process capability improvements (Cp/Cpk) and ensure stable production performance.\n\nEquipment Ownership\n\nProvide daily engineering support for SMT equipment such as:\n\nStencil printer\n\nPick‑and‑place machine\n\nReflow oven\n\nSPI (Solder Paste Inspection)\n\nLead troubleshooting and root cause analysis for equipment failures, misplacements, reflow defects, or inspection inaccuracies.\n\nDefine and maintain PM schedules, calibration, and spare parts strategies.\n\nQuality & Yield Improvement\n\nMonitor and analyze yield, defect Paretos, and SPC trends to identify systemic issues.\n\nLead DfX (Design for Assembly, Design for Manufacturability) discussions with design engineering.\n\nImplement corrective actions and sustainable process controls for solder bridging, opens, voiding, tombstoning, and wetting failures.\n\nManufacturing Support\n\nSupport production technicians with process deviations, equipment issues, and new product introductions.\n\nDevelop documentation including WI/SOPs, process parameters, machine setup sheets, and inspection criteria.\n\nDrive cycle time reduction, throughput improvements, and operator training.\n\nCross‑Functional Collaboration\n\nWork closely with:\n\nPlating & Metallization Engineers\n\nPhotolithography Engineers\n\nMechanical/Assembly Engineering\n\nElectrical Test Engineering (FPT, PRVX4)\n\nSupply Chain & Quality\n\nProvide engineering support during prototype builds and customer‑specific configurations.\n\nContinuous Improvement\n\nLead Lean/6σ initiatives to reduce waste, improve flow, and enhance process robustness.\n\nEvaluate and introduce new materials (solder paste, adhesives, fluxes) and improved stencil/hardware designs.\n\nParticipate in equipment justification and capital project planning.\n\nPreferred Qualifications & Experiences:\n\nBachelor’s degree in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, or related field.\n\n3–7 years of SMT or PCB assembly experience (semiconductor, PCBA, or electronics assembly preferred).\n\nStrong understanding of solder paste behavior, reflow principles, component placement strategies, and defect mechanisms.\n\nHands‑on experience with SMT equipment and inspection systems (SPI, AOI).\n\nProficiency with SPC, FMEA, DOE, and root cause problem solving.\n\nExperience in probe card, semiconductor test hardware, or high‑precision PCB manufacturing.\n\nFamiliarity with high‑density BGAs, fine‑pitch components, and micro‑assembly.\n\nKnowledge of CAM/EDA data for stencil/paste aperture optimization.\n\nLean/6σ Green Belt or Black Belt certification.\n\nExperience with MES systems and factory automation.\n\nSuccess Traits:\n\nStrong ownership mindset and ability to lead daily factory support.\n\nExcellent troubleshooting skills and a structured approach to problem solving.\n\nAbility to work cross‑functionally in a fast‑paced, high‑mix environment.\n\nClear communication and documentation discipline.\n\nPassion for continuous improvement and operational excellence.\n\nSkills:\n\nAssembly Manufacturing, Assembly Operations, Integration Development, Perform Testing, Process Performance, Product Assembly, Test Analysis, Test Evaluation\n\nEducation & Experience:\n\nMinimum of 8 years of related experience with a Bachelor’s degree; or 6 years and a Master’s degree; or a PhD with 3 years experience; or equivalent experience | Required\n\nPay Range:\n\n$136,200.00 - $178,815.00\n\nPay Range Explained:\n\nThis role in Livermore, California pays between $136,200.00 and $178,815.00 per year, depending on your experience, skills, and background. Pay may vary in other locations. We offer a full benefits package, including medical, dental, vision, life insurance, disability coverage, a 401(k) with company match, employee stock purchase plan (ESPP), and paid time off. You’ll also be eligible for quarterly profit-sharing bonuses and flexible spending or savings accounts.\n\nEqual Employment Opportunity Statement\n\nFormFactor 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.\n\nFor roles that are designated as remote-eligible, employees cannot be located in: AL, AK, AR, DE, GA, HI, IL, IA, 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.","company":"Formfactor","rawCompany":"formfactor","city":"Livermore","state":"CA","isRemote":false,"isActive":true,"createdAt":"2026-10-02T12:54:44.382Z","occupations":[{"code":"17-2072.00","title":"Electronics Engineers, Except Computer","slug":"electronics-engineers-except-computer"},{"code":"17-2199.06","title":"Microsystems Engineers","slug":"microsystems-engineers"},{"code":"17-2112.03","title":"Manufacturing Engineers","slug":"manufacturing-engineers"}],"industries":[{"code":"334418","title":"Printed Circuit Assembly (Electronic Assembly) Manufacturing","slug":"printed-circuit-assembly-electronic-assembly-manufacturing"},{"code":"334419","title":"Other Electronic Component Manufacturing","slug":"other-electronic-component-manufacturing"},{"code":"334413","title":"Semiconductor and Related Device Manufacturing","slug":"semiconductor-and-related-device-manufacturing"}],"jobPosting":{"@context":"https://schema.org","@type":"JobPosting","title":"Sr Principal Process Development Engineer","description":"Forming Our Future together\n\nFormFactor, 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.\n\nRooted 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.\n\nShift:\n\nThe regular hours for this position are day shift.\n\nJob Description:\n\nThe Sr Principal Process Development Engineer is responsible for owning, optimizing, and supporting Surface Mount Technology processes used in probe card manufacturing. This role ensures high‑quality PCB assembly, stable process capability, and predictable output across pick‑and‑place, reflow, inspection, and associated upstream/downstream steps. The engineer provides technical leadership for SMT line performance, defect reduction, equipment improvements, and cross‑functional integration with plating, lithography, mechanical assembly, and electrical test teams.\n\nKey Responsibilities:\n\nSMT Process Engineering\n\nDevelop, qualify, and maintain SMT processes, solder paste selection, solder paste injection and inspection, reflow profiling, and placement parameters.\n\nOwn recipe creation and optimization for high‑density advanced probe card PCBs.\n\nDrive process capability improvements (Cp/Cpk) and ensure stable production performance.\n\nEquipment Ownership\n\nProvide daily engineering support for SMT equipment such as:\n\nStencil printer\n\nPick‑and‑place machine\n\nReflow oven\n\nSPI (Solder Paste Inspection)\n\nLead troubleshooting and root cause analysis for equipment failures, misplacements, reflow defects, or inspection inaccuracies.\n\nDefine and maintain PM schedules, calibration, and spare parts strategies.\n\nQuality & Yield Improvement\n\nMonitor and analyze yield, defect Paretos, and SPC trends to identify systemic issues.\n\nLead DfX (Design for Assembly, Design for Manufacturability) discussions with design engineering.\n\nImplement corrective actions and sustainable process controls for solder bridging, opens, voiding, tombstoning, and wetting failures.\n\nManufacturing Support\n\nSupport production technicians with process deviations, equipment issues, and new product introductions.\n\nDevelop documentation including WI/SOPs, process parameters, machine setup sheets, and inspection criteria.\n\nDrive cycle time reduction, throughput improvements, and operator training.\n\nCross‑Functional Collaboration\n\nWork closely with:\n\nPlating & Metallization Engineers\n\nPhotolithography Engineers\n\nMechanical/Assembly Engineering\n\nElectrical Test Engineering (FPT, PRVX4)\n\nSupply Chain & Quality\n\nProvide engineering support during prototype builds and customer‑specific configurations.\n\nContinuous Improvement\n\nLead Lean/6σ initiatives to reduce waste, improve flow, and enhance process robustness.\n\nEvaluate and introduce new materials (solder paste, adhesives, fluxes) and improved stencil/hardware designs.\n\nParticipate in equipment justification and capital project planning.\n\nPreferred Qualifications & Experiences:\n\nBachelor’s degree in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, or related field.\n\n3–7 years of SMT or PCB assembly experience (semiconductor, PCBA, or electronics assembly preferred).\n\nStrong understanding of solder paste behavior, reflow principles, component placement strategies, and defect mechanisms.\n\nHands‑on experience with SMT equipment and inspection systems (SPI, AOI).\n\nProficiency with SPC, FMEA, DOE, and root cause problem solving.\n\nExperience in probe card, semiconductor test hardware, or high‑precision PCB manufacturing.\n\nFamiliarity with high‑density BGAs, fine‑pitch components, and micro‑assembly.\n\nKnowledge of CAM/EDA data for stencil/paste aperture optimization.\n\nLean/6σ Green Belt or Black Belt certification.\n\nExperience with MES systems and factory automation.\n\nSuccess Traits:\n\nStrong ownership mindset and ability to lead daily factory support.\n\nExcellent troubleshooting skills and a structured approach to problem solving.\n\nAbility to work cross‑functionally in a fast‑paced, high‑mix environment.\n\nClear communication and documentation discipline.\n\nPassion for continuous improvement and operational excellence.\n\nSkills:\n\nAssembly Manufacturing, Assembly Operations, Integration Development, Perform Testing, Process Performance, Product Assembly, Test Analysis, Test Evaluation\n\nEducation & Experience:\n\nMinimum of 8 years of related experience with a Bachelor’s degree; or 6 years and a Master’s degree; or a PhD with 3 years experience; or equivalent experience | Required\n\nPay Range:\n\n$136,200.00 - $178,815.00\n\nPay Range Explained:\n\nThis role in Livermore, California pays between $136,200.00 and $178,815.00 per year, depending on your experience, skills, and background. Pay may vary in other locations. We offer a full benefits package, including medical, dental, vision, life insurance, disability coverage, a 401(k) with company match, employee stock purchase plan (ESPP), and paid time off. You’ll also be eligible for quarterly profit-sharing bonuses and flexible spending or savings accounts.\n\nEqual Employment Opportunity Statement\n\nFormFactor 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.\n\nFor roles that are designated as remote-eligible, employees cannot be located in: AL, AK, AR, DE, GA, HI, IL, IA, 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.","datePosted":"2026-10-02T12:54:44.382Z","dateModified":"2026-10-02T12:54:44.382Z","hiringOrganization":{"@type":"Organization","name":"Formfactor","sameAs":"https://jobsearcher.com"},"jobLocation":{"@type":"Place","address":{"@type":"PostalAddress","addressLocality":"Livermore","addressRegion":"CA","addressCountry":"US"}},"identifier":{"@type":"PropertyValue","name":"JobSearcher","value":"128c5b1d6a1bc4e90a56712a"},"url":"https://jobsearcher.com/jobs/128c5b1d6a1bc4e90a56712a"}}