Assistant Engineer - Cable Harnessing

Job description

Roles & Responsibilities • Program, set up, and operate automatic wire processing machines for cutting, stripping, crimping, sealing, and marking. • Develop and validate cable harness manufacturing processes for new product introduction (NPI) and mass production. • Select and qualify applicators, crimp tools, wire guides, and terminals based on customer specifications. • Optimize machine parameters such as strip length, crimp height, pull force, seal position, and wire length. • Perform first-off approval and process validation before releasing production. • Conduct crimp cross-section analysis, crimp height measurement, pull force testing, and visual inspection as per IPC/WHMA-A-620 standards. • Troubleshoot machine alarms, feeding issues, crimp defects, and wire processing abnormalities to minimize downtime. • Plan and execute preventive maintenance, calibration, and tooling replacement for Komax machines. • Prepare and maintain machine setup sheets, work instructions, process parameters, and validation records. • Support engineering builds, pilot production, and production ramp-up while achieving customer delivery schedules. • Analyze production data and improve OEE, cycle time, machine utilization, and Overall Equipment Effectiveness. • Coordinate with Quality, Production, Maintenance, SCM, and suppliers to resolve cable harness manufacturing issues. • Implement engineering changes (ECN/ECR), validate new terminals, wires, connectors, and applicators. • Train operators and technicians on Komax machine operation, troubleshooting, safety, and quality requirements. • Drive continuous improvement through Lean Manufacturing, 5S, Poka-Yoke, scrap reduction, and defect prevention to achieve FPY, productivity, and customer quality targets.