FormFactor

Senior Manufacturing Process Engineer

FormFactor$94K — $123K *
Manufacturing & Automotive
5 - 7 years of experience
Job Overview by Ladders

Qualifications

  • Bachelor's degree in Engineering and 5+ years relevant experience or a Master's with 3+ years; PhD candidates also considered.
  • Proven experience in manufacturing process design and validation.
  • Strong background in continuous improvement methodologies such as Lean and 6S.
  • Expertise in root cause analysis techniques (8D, 5 Whys, Ishikawa).
  • Familiarity with cryogenic systems and semiconductor manufacturing processes.
  • Ability to conduct Data Analysis and interpret manufacturing metrics effectively.

Responsibilities

  • Lead and own complex manufacturing process development and design transfer.
  • Define, execute, and document process validation plans and SOPs.
  • Establish manufacturing methods for technically complex assemblies.
  • Independently address manufacturing challenges and drive root cause investigations.
  • Analyze data trends to identify improvement opportunities and reduce defects.
  • Conduct Design for Manufacturability (DFM) reviews and provide critical feedback during design phases.
  • Mentor junior engineers and standardize best practices in manufacturing processes.

Benefits

  • Comprehensive benefits package including medical, dental, and vision insurance.
  • 401(k) plan with company match.
  • Employee Stock Purchase Plan (ESPP).
  • Qualification for quarterly profit-sharing bonuses.
  • Paid time off for work-life balance.
  • Flexible spending or savings accounts.
Full Job Description
Shift:
The regular hours for this position are day shift.

Job Description:

We are seeking a Senior Manufacturing Process Engineer to join our Boulder Operations team supporting the manufacturing of our Quantum Cryogenic product portfolio. This role independently owns complex manufacturing process development, design transfer, and technical risk reduction across cryogenic and semiconductor test product lines.

Drawing on deep process engineering expertise, this position converts R&D and prototype knowledge into controlled, scalable manufacturing processes. The role provides technical guidance to junior engineers and leads cross-functional problem solving that directly impacts production quality, repeatability, and schedule. This engineer serves as a recognized technical authority within Manufacturing Engineering and contributes to advancing overall manufacturing readiness and process maturity.

Key Responsibilities:

Process Development & Design Transfer
  • Lead complex process development and design transfer activities, converting R&D and prototype builds into validated, production-ready manufacturing processes.
  • Define and execute process validation plans, readiness gate deliverables, and SOP development.
  • Establish manufacturing methods for technically complex assemblies where processes are not yet fully defined.


Process Ownership & Execution
  • Own assigned manufacturing process areas with minimal oversight, including process definition, tooling/fixture requirements, documentation, and validation.
  • Ensure processes are controlled, repeatable, and scalable across product lines.


Problem Solving & Root Cause Analysis
  • Independently solve manufacturing challenges of diverse scope and moderate-to-high complexity.
  • Lead structured root cause investigations using methodologies such as 8D, 5 Whys, and Fishbone/Ishikawa diagrams.
  • Drive corrective and preventive actions for recurring or complex process issues.


Data Analysis & Continuous Improvement
  • Analyze manufacturing, quality, and yield data to identify trends and improvement opportunities.
  • Lead continuous improvement initiatives using Lean/6S/PDCA methodologies.
  • Establish and track KPIs; deliver measurable improvements in First-pass yield, Defect reduction, Cycle time, and Rework rates.

Cross-Functional Collaboration & DFM
  • Conduct Design for Manufacturability (DFM) reviews with Product Engineering.
  • Provide structured feedback on process risk, assembly complexity, and production feasibility.
  • Represent Manufacturing Engineering in design reviews and technical forums.


Risk Identification & Mitigation
  • Identify and communicate manufacturing risks impacting quality, repeatability, or schedule.
  • Partner cross-functionally to proactively develop and implement mitigation strategies.


Documentation & Standards
  • Develop and maintain comprehensive manufacturing documentation, including Process flow maps, Work instructions and travelers, and Process qualification records.
  • Establish and standardize best practices across product lines.


Leadership & Technical Guidance
  • Provide mentorship and technical guidance to junior engineers.
  • Promote best practices in process engineering, documentation, and manufacturing standards.


Work Environment:
  • Combination of office and laboratory/manufacturing floor environment.
  • Ability to lift up to 25 lbs as needed.
  • Use of standard office and lab equipment (computers, test setups, tools).
  • Travel: Up to 15%.


Skills:
Continuous Improvement, Cross-Functional Collaboration, Cryogenic Systems, Data Analysis, Design for Manufacturing (DFM), Engineering Change Order (ECO), Geometric Dimensioning And Tolerancing (GD&T), Manufacturing Process Design, Manufacturing Process Engineering, Manufacturing Process Validation, New Product Introduction (NPI), Process Development (PD), Process Failure Mode Effects Analysis (PFMEA), Process Flow Documentation, Root Cause Analysis (RCA), Semiconductor Manufacturing, Writing Work Instructions

Education & Experience:
Minimum of 5 years of related experience with a Bachelor's degree; or 3 years and a Master's degree; or a PhD without experience; or equivalent work | Required

Pay Range:
$94,100.00 - $123,480.00

Pay Range Explained:
This role in Boulder, Colorado pays between $94,100.00 and $123,480.00 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.

About FormFactor

FormFactor, Inc. is a leading provider of essential test and measurement technologies along the full IC 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. FormFactor is headquartered in Livermore, California with operations worldwide.
Learn more about FormFactor
Size
2,293 employees
Market Cap
$1.7 billion
Industry
Net Income
$78.5 million
Founded
1995
5 Year Trend
+14.9%
Revenue
$693.6 million
NASDAQ

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