Sr. Staff Integration Engineer

The Sr. Staff Integration Engineer is responsible for defining, optimizing, and sustaining end-to-end process integration flows for probe card manufacturing in a high-volume semiconductor environment. This role serves as a senior technical authority, integrating complex unit processes across wafer-level fabrication, MEMS, precision assembly, interconnect, and electrical test.

The position drives yield performance, manufacturability, and scalability by aligning cross-functional engineering, operations, and product teams. The role operates with significant autonomy, leading cross-module problem solving, technology transfer, and continuous improvement initiatives, while mentoring engineers and influencing integration strategy across sites.

This role acts as the primary technical interface between process modules, ensuring integrated process flows meet product, quality, and reliability requirements., Process Integration Ownership

• Define, own, and continuously improve end-to-end process integration flows for probe card manufacturing

• Ensure alignment of unit process performance to product-level electrical, mechanical, and reliability targets

• Identify and manage integration risks, interactions, and trade-offs across modules

Yield & Performance Optimization

• Lead integration-level yield improvement initiatives using data-driven analysis and structured problem solving

• Investigate complex yield excursions, defect mechanisms, and cross-process interactions

• Drive defect reduction, process capability improvements, and cycle time reduction

New Product Introduction (NPI) & Technology Transfer

• Lead integration activities for NPI, pilot builds, and ramp to high-volume manufacturing

• Own integration readiness criteria including process stability, control plans, and manufacturability

• Support cross-site technology transfer and process replication with strong change control discipline

Process Flow Development & Control

• Develop and maintain integrated process flows, specifications, and control strategies

• Define critical process parameters, control points, and monitoring strategies (SPC/FDC)

• Ensure robust process window characterization and documentation

Cross-Functional Technical Leadership

• Act as the technical integration interface across Process, Equipment, Product, Yield, Quality, and Manufacturing teams

• Influence design for manufacturability (DfM) and design for reliability (DfR)

• Partner with operations on process stability, tool readiness, and production performance

Data Analysis & Problem Solving

• Analyze inline, electrical test, metrology, and defect data to identify integration gaps

• Design and execute complex DOEs to resolve multi-variable process interactions

• Utilize structured methodologies (DMAIC, 8D) for root cause analysis

Change Management & Governance

• Evaluate, approve, and implement changes to processes, materials, equipment, and flows

• Ensure compliance with change control processes, qualification standards, and documentation requirements

• Maintain traceability and configuration control across process changes

Mentorship & Technical Influence

• Mentor and guide junior and senior engineers on integration practices and problem solving

• Provide technical leadership on cross-functional and multi-site initiatives

• Influence long-term integration strategy and technology roadmap

8D Report, 8D Report, Change Management, Cross-Functional Groups, Cross-Functional Work, Data Analysis, Defect Metrology, Defect Reduction, Defects Analysis, Design for Manufacturing (DFM), Design for Reliability (DFR), Design of Experiments (DOE), DMAIC, DMAIC Process Improvement, Electrical Failure Analysis, Electrical Validation, Electroplating, Etching, Failure Analysis, Manufacturing Execution Systems (MES), Manufacturing Scale-Up, MES Integration, Metrology, Microelectromechanical Systems (MEMS), New Product Introduction (NPI) {+ 18 more}, Minimum of 12 years of related experience with a Bachelor's degree; or 8 years and a Master's degree; or a PhD with 5 years experience; or equivalent experience | Required

Pulled from the full job description

• Employee stock purchase plan
• Health insurance
• 401(k) matching
• Paid time off
• Vision insurance
• Dental insurance
• Life insurance, $163,400.00 - $214,410.00

Pay Range Explained: This role in Livermore, California pays between $163,400.00 and $214,410.00 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.

FormFactor, 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. Rooted 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.