Shift:The regular hours for this position are day shift.
Job Description:The
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.
Key Responsibilities: SMT Process Engineering- Develop, qualify, and maintain SMT processes, solder paste selection, solder paste injection and inspection, reflow profiling, and placement parameters.
- Own recipe creation and optimization for high-density advanced probe card PCBs.
- Drive process capability improvements (Cp/Cpk) and ensure stable production performance.
Equipment Ownership- Provide daily engineering support for SMT equipment such as:
- Stencil printer
- Pick-and-place machine
- Reflow oven
- SPI (Solder Paste Inspection)
- Lead troubleshooting and root cause analysis for equipment failures, misplacements, reflow defects, or inspection inaccuracies.
- Define and maintain PM schedules, calibration, and spare parts strategies.
Quality & Yield Improvement- Monitor and analyze yield, defect Paretos, and SPC trends to identify systemic issues.
- Lead DfX (Design for Assembly, Design for Manufacturability) discussions with design engineering.
- Implement corrective actions and sustainable process controls for solder bridging, opens, voiding, tombstoning, and wetting failures.
Manufacturing Support- Support production technicians with process deviations, equipment issues, and new product introductions.
- Develop documentation including WI/SOPs, process parameters, machine setup sheets, and inspection criteria.
- Drive cycle time reduction, throughput improvements, and operator training.
Cross-Functional Collaboration- Work closely with:
- Plating & Metallization Engineers
- Photolithography Engineers
- Mechanical/Assembly Engineering
- Electrical Test Engineering (FPT, PRVX4)
- Supply Chain & Quality
- Provide engineering support during prototype builds and customer-specific configurations.
Continuous Improvement- Lead Lean/63 initiatives to reduce waste, improve flow, and enhance process robustness.
- Evaluate and introduce new materials (solder paste, adhesives, fluxes) and improved stencil/hardware designs.
- Participate in equipment justification and capital project planning.
Preferred Qualifications & Experiences: - Bachelor9s degree in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, or related field.
- 3-7 years of SMT or PCB assembly experience (semiconductor, PCBA, or electronics assembly preferred).
- Strong understanding of solder paste behavior, reflow principles, component placement strategies, and defect mechanisms.
- Hands-on experience with SMT equipment and inspection systems (SPI, AOI).
- Proficiency with SPC, FMEA, DOE, and root cause problem solving.
- Experience in probe card, semiconductor test hardware, or high-precision PCB manufacturing.
- Familiarity with high-density BGAs, fine-pitch components, and micro-assembly.
- Knowledge of CAM/EDA data for stencil/paste aperture optimization.
- Lean/63 Green Belt or Black Belt certification.
- Experience with MES systems and factory automation.
Success Traits: - Strong ownership mindset and ability to lead daily factory support.
- Excellent troubleshooting skills and a structured approach to problem solving.
- Ability to work cross-functionally in a fast-paced, high-mix environment.
- Clear communication and documentation discipline.
- Passion for continuous improvement and operational excellence.
Skills: Assembly Manufacturing, Assembly Operations, Integration Development, Perform Testing, Process Performance, Product Assembly, Test Analysis, Test Evaluation
Education & Experience: Minimum of 8 years of related experience with a Bachelor9s degree; or 6 years and a Master9s degree; or a PhD with 3 years experience; or equivalent experience | Required
Pay Range:$136,200.00 - $178,815.00
Pay Range Explained:This 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. You9ll also be eligible for quarterly profit-sharing bonuses and flexible spending or savings accounts.
