Process Engineer - Cable Harnessing

Larsen & Toubro Limited; Coimbatore District; On-site; INR 1,200,000 - 1,800,000; Full time

Job summary

Larsen & Toubro Limited, Coimbatore Campus, is seeking an experienced engineer to drive process development for cable assembly and related manufacturing steps. The role covers design of fixtures, tooling, SOPs and process controls to ensure high quality production.

You will execute trials, validate first-parts and establish process capability, while improving cycle times and line balance. Collaboration with multiple teams is essential for successful NPI and mass ramp-up.

Qualifications

• BE with relevant manufacturing/engineering experience.
• 4–7 years of experience in process development and manufacturing.
• Familiar with PFMEA, SOPs, and NPI practices.

Responsibilities

• Develop and establish efficient manufacturing processes for cable cutting, stripping, crimping, terminal insertion, routing, taping, sleeving and final assembly.
• Conduct trials, first-piece validation and process capability studies before mass release.
• Prepare and maintain SOPs, Work Instructions, Process Flow, PFMEA, Control Plan and SOP parameters.
• Establish and monitor crimp height, width, pull-force and applicator parameters.
• Perform time studies, set standard cycle times and optimize line balance.
• Design harness boards, fixtures, templates and tooling to improve accuracy and productivity.
• Analyze defects using RCA/5 Why/8D and implement corrective actions to achieve zero defects.
• Develop and optimize electrical test processes (continuity, Hi-Pot, insulation resistance).
• Support NPI and pilot/mass production builds with process trials and ramp-up.
• Manage ECN/ECR changes with proper engineering change control.

Skills

PFMEA

Process Validation

Kaizen

Lean Six Sigma

NPI Management

Quality Improvement

SOP

Cycle Time

Fixture Design

Poka-Yoke

Electrical Test

Education

Bachelor of Engineering (BE)

Job description

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

End Date 12 Apr 2027

Required Experience 4 - 7 years

Skills

Knowledge & Posting Location

PFMEA Process Flow Chart (PFC). Drawing verification Tooling Design Fixture Design RCA G8D SOP NPI Management Kaizen Continuous Improvement Lean Six Sigma

Bachelor of Engineering (BE)

Job Description

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.