Assistant Engineer - Cable Harnessing

Larsen & Toubro Limited; Coimbatore District; On-site; INR 500,000 - 750,000; Full time

Job summary

DEIC-L&T Precision Engineering & Systems IC in Coimbatore is hiring a BE engineer to program, set up, and optimize automatic wire processing equipment for cutting, stripping, crimping, sealing, and marking. The role focuses on developing and validating cable harness processes for both NPI and mass production, ensuring quality and delivery targets.

You will select applicators and tooling, refine process parameters, and perform validation activities in accordance with IPC/WHMA-A-620.

Qualifications

• BE degree or equivalent in engineering.
• 2–5 years of experience in cable harness or related manufacturing.
• Knowledge of IPC/WHMA-A-620 standards is beneficial.

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 NPI and mass production.
• Select and qualify applicators, crimp tools, wire guides, and terminals per customer specs.
• Optimize machine parameters like strip length, crimp height, pull force, seal position, and wire length.
• Perform first-off approval and process validation before release to production.
• Conduct crimp cross-section analysis, crimp height measurement, pull force testing, and visual inspection.
• Troubleshoot machine alarms, feeding issues, crimp defects, and wire processing abnormalities to minimize downtime.
• Plan 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 ramp-up while meeting delivery schedules.
• Analyze production data and improve OEE, cycle time, and machine utilization.
• Coordinate with Quality, Production, Maintenance, SCM, and suppliers to resolve harness issues.
• Implement ECN/ECR changes, validate new terminals, wires, and applicators.
• Train operators on Komax operation, troubleshooting, safety, and quality requirements.
• Drive Lean initiatives, 5S, Poka-Yoke, and FPY improvements to meet quality targets.

Skills

Analytical skill

Method validation

Tooling design

Process automation

Manufacturing quality

Programmable logic

Lean manufacturing

Education

Bachelor of Engineering (BE)

Tools

Komax machines

Crimp tools

Wire guides

Terminals

Job description

• DEIC-L&T Precision Engineering & Systems IC
• Coimbatore Campus

Posted On 10 Sep 2026

End Date 09 Mar 2027

Required Experience 2 - 5 years

Skills

Knowledge & Posting Location

Analytical Method Validation Tooling Design Process Automation Manufacturing Quality Programmable Logic Lean Manufacturing

Bachelor of Engineering (BE)

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.