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.