Assistant Engineer - Cable Harnessing

Larsen & Toubro; Coimbatore District; On-site; INR 900,000 - 1,300,000; Full time

Job summary

Larsen & Toubro in Coimbatore, Tamil Nadu, India seeks a manufacturing engineer to program, set up, and operate automatic wire processing machines for cutting, stripping, crimping, sealing, and marking.

You will develop and validate cable harness processes for NPI and mass production, select and qualify applicators and tools, and optimize machine parameters to meet quality and delivery goals.

Qualifications

• Experience with wire harness manufacturing processes and automation.
• Knowledge of IPC/WHMA-A-620 standards is preferred.
• Experience with NPI and mass production transitions.

Responsibilities

• Program, set up, and operate automatic wire processing machines.
• Develop and validate cable harness processes for NPI and mass production.
• Select and qualify applicators, crimp tools, wire guides, and terminals.

Skills

Crimping

Troubleshooting

Process optimization

Lean Manufacturing

5S

Poka-Yoke

OEE improvement

Tools

Komax machines

Job description

• 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.