Process Engineer - Cable Harnessing

Larsen & Toubro; Coimbatore District; On-site; INR 700,000 - 1,200,000; Full time

Job summary

Larsen & Toubro in Coimbatore invites qualified engineers to join the manufacturing engineering team. You will develop and optimize processes for cable cutting, stripping, crimping, terminal insertion, routing, taping, sleeving and final assembly.

You will validate processes, prepare SOPs and work instructions, lead quality improvement initiatives, and collaborate across Production, Quality, NPI and Design Engineering to ensure smooth mass production ramp-up.

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.

Job description

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.