Sr Staff Reliability Engineer

Forming Our Future together

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.

Shift:

The regular hours for this position are day shift.

Job Description:

The Sr. Staff Reliability Engineer provides recognized technical leadership in reliability engineering, failure analysis, product qualification, and process quality assurance. Operating as a subject matter expert, this role leads complex technical investigations, develops reliability strategies for advanced semiconductor and MEMS technologies, and influences product and process decisions across multiple engineering disciplines.

This individual independently drives high-impact initiatives that improve product robustness, accelerate new product introductions, enhance failure analysis capabilities, and support long-term reliability and quality objectives. The role serves as a key technical resource for resolving critical customer, manufacturing, and product reliability challenges while mentoring engineers and advancing organizational technical expertise.

Key Responsibilities:

Reliability Engineering & Product Qualification

• Lead the development and execution of reliability qualification strategies for new products, design changes, material modifications, process improvements, and manufacturing transfers.

• Define reliability requirements, risk assessments, qualification methodologies, stress conditions, sampling plans, and acceptance criteria based on product and system-level risks.

• Drive qualification activities to ensure product performance, reliability, and customer requirements are achieved prior to release.

• Develop reliability models and data-driven approaches to assess product lifetime, degradation mechanisms, and long-term field performance.

Failure Analysis & Root Cause Investigation

• Lead complex failure analysis investigations involving product, process, manufacturing, and customer-returned materials.

• Utilize advanced analytical techniques including SEM/EDS, FIB, FTIR, X-ray analysis, cross-sectioning, nano-indentation, materials characterization, and electrical/mechanical testing to determine failure mechanisms.

• Establish clear root-cause conclusions and drive corrective actions to prevent recurrence.

• Serve as the technical escalation point for critical reliability, qualification, and customer quality issues.

Process Quality & Continuous Improvement

• Partner with Design Engineering, Product Engineering, Quality, Manufacturing, and Supply Chain teams to identify reliability risks and implement effective corrective and preventive actions (CAPA).

• Apply statistical methodologies, including SPC, DOE, JMP, and reliability modeling techniques, to evaluate product and process performance, identify trends, and improve manufacturing robustness.

• Drive data-driven decision making through quantitative analysis, risk assessments, and reliability reporting.

• Support continuous improvement initiatives focused on yield enhancement, defect reduction, and product reliability optimization.

Technical Leadership & Strategic Influence

• Provide technical leadership across multiple programs and product lines, influencing engineering decisions through deep expertise and sound technical judgment.

• Lead cross-functional teams in resolving complex technical challenges and developing long-term reliability strategies.

• Establish best practices, technical standards, and methodologies for reliability engineering and failure analysis activities.

• Maintain and advance laboratory capabilities, test methodologies, and analytical tools to support evolving technology requirements.

• Mentor and develop engineers and technicians through technical coaching, knowledge sharing, and guidance on reliability engineering principles and experimental design.

Communication & Reporting

• Prepare and present technical findings, reliability assessments, qualification reports, and risk evaluations to engineering leadership and senior management.

• Communicate complex technical concepts and recommendations effectively to cross-functional stakeholders.

• Influence business and technical decisions through data, analysis, and demonstrated subject matter expertise.

Preferred Qualifications & Experiences:

• Strong technical expertise in semiconductor or MEMS reliability engineering, failure analysis, product qualification, and process quality.

• Demonstrated ability to independently lead technical investigations, qualification activities, and multiple concurrent projects.

• Hands-on experience with advanced material characterization and failure-analysis instrumentation, including SEM, FIB, physical sectioning, and mechanical test systems.

• Strong proficiency in statistical analysis and reliability tools, including SPC, DOE, and JMP.

• Experience providing technical leadership, mentoring, and driving cross-functional problem resolution.

• Strong written and verbal communication skills, with the ability to interface effectively with technical teams, manufacturing organizations, and management.

Skills:

Cross Section, Cross Sectional Analysis, Failure Analysis, Focused Ion Beam (FIB), Fourier-Transform Infrared Spectroscopy (FTIR), Instron Mechanical Testing, Materials Characterization, Microelectromechanical Systems (MEMS), Nanoindentation, Probe Cards, Quality Assurance (QA), Reliability Engineering, Reliability Testing, SAS JMP (Statistical Software), Scanning Electron Microscopy / Energy Dispersive X-Ray Spectroscopy (SEM/EDS), Semiconductors, Statistical Analysis, Statistical Process Control (SPC), Tribometers, Wafer Probing

Education & Experience:

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

Pay Range:

$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.

Equal Employment Opportunity Statement

FormFactor is an equal opportunity employer. FormFactor complies with all national, state, and local laws that seek to promote equal opportunities for any applicant or employee without regard to age, race, color, gender, gender identity/expression, national origin, sexual orientation, religion, disability, marital status, pregnancy or related condition, military service, or any other legally protected characteristics. These protections apply to all aspects of employment, including but not limited to, recruitment, hiring, training, promotions, and compensation.

For roles that are designated as remote-eligible, employees cannot be located in: AL, AK, AR, DE, GA, HI, IL, IA, LA, ME, MD, MS, MO, NE, NV, NJ, NM, ND, OK, PA, RI, SC, SD, TN, WV, WI, WY. This list is continuously evolving and being updated, please check back with us if the state you live in is on the exclusion list. A role is remote-eligible only when it is listed as "Remote" in the job location.