Process Engineer - Cable Harnessing

Roles & Responsibilities

Process Development – Develop and establish efficient manufacturing processes for cable cutting, stripping, crimping, terminal insertion, routing, taping, sleeving and final assembly.

Process Validation – Conduct trials, first-piece validation and process capability studies before releasing processes for mass production.

Work Instructions & Documentation – Prepare and maintain SOPs, Work Instructions, Process Flow, PFMEA, Control Plan and standard operating parameters.

Crimping Process Control – Establish and monitor crimp height, crimp width, pull-force and applicator parameters to ensure consistent termination quality.

Cycle Time & Line Balancing – Conduct time studies, establish standard cycle times and optimize workstation and manpower allocation.

Jig, Fixture & Tooling Development – Design and implement harness boards, fixtures, templates, poka-yoke devices and special tools to improve assembly accuracy and productivity.

Quality Improvement – Analyze process defects, conduct RCA/5 Why/8D and implement corrective and preventive actions to achieve Zero Defect.

Electrical Test Process – Develop and optimize continuity, open/short, Hi-Pot, insulation resistance and functional testing processes.

NPI & New Product Introduction – Support prototype, pilot and mass-production builds, including process trials, validation and production ramp-up.

Engineering Change Management – Implement drawing, BOM, specification and process changes through proper ECN/ECR control.

Poka-Yoke & Error Proofing – Identify potential assembly errors and implement mechanical, electrical and software-based error-proofing solutions.

Productivity Improvement – Drive cycle-time reduction, manpower optimization, UPH improvement, yield improvement and manufacturing cost reduction.

Lean & Continuous Improvement – Implement 5S, Kaizen, VSM, waste elimination and other Lean Manufacturing initiatives.

Machine & Tooling Readiness – Coordinate with Maintenance and suppliers for machine setup, preventive maintenance, calibration and tooling availability.

Cross-Functional Support – Work closely with Production, Quality, SCM, Maintenance, NPI and Design Engineering teams to resolve process issues and ensure stable mass production.