Micro Assembly Process Engineer

Job Title

Micro Assembly Process Engineer

Role Summary

Lead and improve micro-assembly and probe card production processes at the Livermore manufacturing site. The role focuses on troubleshooting and repairing complex probe cards and sub-assemblies, supporting new product introductions (NPI), and driving process improvements to meet quality and throughput targets.

This is an onsite manufacturing engineering role working with technicians, metrology equipment, automated assembly systems, and cross-functional teams to scale processes from low- to high-volume manufacturing.

Experience Level

Mid-level. The posting requires approximately 5 years of progressive relevant experience.

Responsibilities

Key day-to-day responsibilities include:

• Troubleshoot, repair, and maintain probe cards and precision sub-assemblies.
• Support Manufacturing Engineering by identifying, prioritizing, and implementing process improvements.
• Coach and train technicians; perform Core trainer training and certification across shifts.
• Participate in tests and experiments to improve processes or develop new products.
• Modify automated assembly system parameters, update procedures, and introduce new tooling for products.
• Support first-article activities: substrate alignment, tooling introduction, setup, verification, metrology, and rework.
• Manage and participate in assembly equipment hardware and software upgrades to meet quality and throughput goals.
• Contribute to equipment capacity increases and CapEx projects to meet production demand.

Requirements

Must-have technical skills and experience.

• Minimum 5 years of progressive experience as a Field Service/Application Engineer, Quality Control Engineer, or similar role.
• Experience managing medium-to-complex analysis models in JMP for process data, yield analysis, quality controls, and DOE.
• Proven ability to troubleshoot probe card issues across components and repair precision electromechanical assemblies using root-cause analysis and standard measurement instruments.
• Hands-on experience with NPI processes, equipment assessment, and customization.
• Experience driving continuous process improvement (CPI) in micro-assembly processes and leading improvement projects.
• Practical use of microscopes, micromanipulators, and metrology tools for alignment and inspection.
• Experience transferring processes from development to Low Volume Manufacturing (LVM) and High Volume Manufacturing (HVM).
• Dimensional inspection and alignment verification using optical measurement systems, calipers, micrometers, and dial indicators.
• Experience establishing HVM processes, including documentation, specifications, and manufacturing work instructions.

Education Requirements

Bachelor’s degree or foreign equivalent in Manufacturing Engineering, Mechanical Engineering, or a related technical field.

About the Company

Company: FormFactor

Headquarters: Livermore, California, United States

FormFactor provides test and measurement technologies and services for the semiconductor industry across the product lifecycle — including characterization, modeling, reliability, design debug, qualification and production test. The company serves customers globally through facilities in Asia, Europe, and North America.