Assistant Engineer - Cable Harnessing

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.