Sr. Metrology Process Engineer

Livermore, CA

FormFactor, Inc.

We live in a mobile driven world where technology is constantly improving. Semiconductor manufacturers need a partner as they pioneer and drive the most advanced integrated circuits (ICs) ever made. FormFactor is the world’s leading supplier of semiconductor test and measurement products used to test the ICs that power the majority of smart phones and tablets on the planet, as well as electronic systems used in computing, consumer, automotive, Artificial Intelligence (AI) and other applications. We are a big company with a small time feel. Working at FormFactor gives you the opportunity to work with cutting edge technology, have a direct influence on next generation products hitting the market and drive the overall growth and development of the semiconductor industry.

We are a fast-paced, agile, growing company that values diversity of thought and constantly strives for a more diverse, inclusive environment. We are looking for enthusiastic, talented individuals who can thrive in a changing and challenging environment.

Purpose

In the role of MEMS Process Engineer, you will be responsible to apply measurement sciences, mathematics and physics for the development, implementation, and continuous improvement of various calibrated equipment and systems used to manufacture MEMS-based products used in advanced memory and SOC probe cards.

Essential Duties and Responsibilities

• Design and develop various measurement methodologies and tooling used for electrical, dimensional, optical and mechanical characterization for MEMS based products.
• Engineering ownership for sustaining, improving, and unit process developing (in such areas as Quality, metrology, test).
• Drive the ramp and scale-up of new metrology and test and micro assembly processes to high volume manufacturing in our state of the art MEMS fabrication facility in Livermore, CA.
• Monitor Outgoing/Incoming Quality Control (OQC/IQC), generate PCP, Customer Audit (CA) processes for OEM sites, evaluate process data to determine failure modes and identify opportunities to improve.
• Conduct periodic reviews of Field/Factory Quality Data with internal engineering groups/OEM partners.
• Assess the manufacturability of new unit processes and process flows.
• Support the specification, evaluation and qualification of fabrication equipment to improve process capabilities.
• Perform daily analysis of data from production and engineering process runs, qualifying changes or additions to manufacturing toolsets and process flows, and designing and executing engineering experiments to either resolve process excursions or to drive process performance improvements.
• Apply Statistical Process Control (SPC) and continuous improvement methodologies to ensure manufacturing processes remain both predictable and capable at the lowest possible operating cost.
• Engage with equipment vendors to improve FFI tool performance and ensure established manufacturing targets for equipment utilization and uptime are met or exceeded.
• Work closely with peers in Research and Development to either utilize existing processes and/or equipment or develop new processes and/or equipment to meet requirements driven by new products and technology roadmaps.
• Own training and implementation of new processes and/or equipment to HVM operations.

Education, Experience, and Skills

• B.S., M.S., in Material Science, Mechanical, Manufacturing or Electrical Engineering, with research related to MEMS, Microfabrication, Machine Design, and or Semiconductor packaging.
• 2+ years of progressive experience as Manufacturing Process Engineer, Quality or Metrology Engineer, or related experience.
• Hands-on experience with advanced metrology and testing systems, experience in any of the following preferred: Tensile and Compressive Force testing systems, CNC-based Automated Metrology Systems, (CMM, VIEW, NEXIV), Thermal Industrial Ovens (Curing, Annealing, Drying), Functional Electrical Test Systems (ITC, PWX, PRVX).
• Experience with calibrating, verification and validating metrology and test equipment are operating in control and measuring within acceptable test re-test errors.
• Manufacturing process development experience. Fixture and tooling, DFM
• Working knowledge of mechanical drawing, GD&T, and metrology design
• A disciplined use of statistical methods to establish robust process controls and healthy process capabilities, analyze process yield, and for experimental design and analysis.
• Work experience with the development of new process technology and capabilities and successful transfer from pilot to high-volume capability.
• Experience in use of Statistical Process Control and Design of Experiments; quality and continuous improvement methodologies such as Failure Mode and Effects Analysis (FMEA), Root-cause Analysis (RCA), and/or Lean Manufacturing, 5’s, 8D, corrective actions, and AutoCad softwares.

FormFactor is committed to providing a work environment where everyone is treated with dignity and respect. We are an Equal Employment Opportunity (EEO) employer and are committed to compliance with all Federal, State, and local laws that prohibit employment discrimination on the basis of age, race, color, sex (including breastfeeding and related conditions), gender (including gender identity and gender expression), national origin, ancestry, sexual orientation, religion, physical or mental disability, marital status, registered domestic partner status, medical condition, military or veteran status, genetic characteristics or information, or any other legally protected characteristic. These protections extend to all employment and management decisions including, but not limited to, recruiting, hiring, training, promotions, pay practices, benefits, disciplinary actions and terminations, and all other terms and conditions of employment.