Wire Harnessing & Electrical Assembly Specialist - Defence Systems

Vir Innovations; Hyderabad; On-site; INR 350,000 - 700,000; Full time

Job summary

Vir Innovations in Hyderabad, India is seeking a Wire Harnessing & Electrical Assembly Specialist to handle end-to-end electrical assembly activities across defence and robotic systems. This role involves assembling wiring harnesses and ensuring quality control through thorough testing and inspection.

The ideal candidate should have 1–4 years of relevant experience, with strong technical skills in wire harness assembly and soldering, along with the ability to work on prototypes.

Qualifications

• 1–4 years of hands-on experience in wire harnessing and electrical assembly.
• Strong hand skills and attention to detail.
• Comfortable working on prototypes and low-volume production.

Responsibilities

• Read and interpret wiring diagrams, pinout tables, and assembly drawings.
• Manufacture and assemble wire harnesses, cable assemblies, and electrical subassemblies.
• Perform crimping, soldering, and connector termination activities.
• Conduct system-level testing and quality inspection of harness assemblies.
• Support process development and continuous improvement initiatives.

Skills

Wire harness assembly

Precision crimping tools usage

Soldering and rework skills

Continuity testing

Harness routing and protection

Troubleshooting

Education

Diploma / ITI / B.Tech in Electrical, Electronics, Mechatronics, ECE, or related field

Job description

Domain: Defence – Robotics, IoT Systems & Training Simulators

This is a purely hands‑on hardware role involving physical assembly and wiring work.

Not suitable for:

• Software‑only candidates (Programming, firmware design, etc.)
• Candidates expecting design‑only or desk‑based roles

Job Overview

We are seeking a hands‑on Wire Harnessing & Electrical Assembly Specialist responsible for end‑to‑end electrical and electro‑mechanical assembly activities across defence and robotic systems. The role involves manufacturing, assembly, testing, inspection, and packaging of wiring harnesses, connectors, PCB assemblies, and integrated electrical subsystems used in mission‑critical products.

Responsibilities

A. Wire Harness Manufacturing & Assembly

• Read and interpret wiring diagrams, pinout tables, assembly drawings, and work instructions.
• Manufacture and assemble wire harnesses, cable assemblies, and electrical subassemblies as per engineering drawings, wiring diagrams, schematics, and BOMs.
• Perform precision wire preparation activities including cutting, measuring, sorting, colour coding, labelling, stripping, routing, and termination of various wire types and gauges.
• Execute crimping, soldering, connector termination, pin insertion/extraction, splicing, and connector assembly activities.
• Route, organize, and bundle wiring harnesses according to design requirements while ensuring maintainability and serviceability.
• Prepare harness kits and subassemblies to support production efficiency and repeatability.
• Build prototype and low‑volume production harnesses for robotics, defence electronics, simulators, and ruggedised systems.
• Ensure correct selection and use of wire gauges, cable types, connectors, shielding materials, and termination methods.

B. PCB & Electrical Assembly

• Perform through‑hole and basic SMT component soldering.
• Assemble PCBs, electrical modules, and subassemblies.
• Integrate harnesses with PCB assemblies and electromechanical systems.
• Install and assemble sensors, switches, relays, actuators, power modules, and communication modules.
• Support prototype builds and rapid iterations.

C. Harness Protection, Bundling & Routing

• Apply wire protection and bundling techniques using heat shrink tubing, braided sleeves, cable ties, spiral wraps, conduits, lacing methods, protective sleeving, and strain‑relief methods.
• Ensure proper cable routing, bend radius management, shielding practices, and separation of power/signal wiring.
• Build ruggedised harnesses capable of withstanding vibration, shock, temperature variation, and harsh operating environments.
• Ensure completed assemblies are professionally organised, labelled, protected, and packaged for deployment.

D. Testing, Inspection & Quality Control

• Perform system‑level testing, continuity testing, polarity checks, insulation checks, connector verification, and functional validation of harness assemblies.
• Inspect crimps, solder joints, connector integrity, wire routing, and labelling quality.
• Verify assemblies against drawings and checklists.
• Identify and troubleshoot harness faults, wiring issues, and assembly defects.
• Ensure assemblies comply with internal quality standards and engineering documentation.
• Support root cause analysis and corrective actions for assembly‑related failures.

E. Process Development & Manufacturing Support

• Assist in developing efficient manufacturing and assembly procedures, process and sequences documentation by analysing and validating processes, standards, specifications, and assembly workflows.
• Support continuous improvement initiatives to improve build quality, repeatability, and throughput.
• Update assembly records and build documentation.
• Provide feedback to engineering teams on manufacturability, assembly complexity, and production optimisation opportunities.
• Support inventory control and management of harness consumables, tools, and production materials.

F. Packaging, Dispatch & End‑to‑End Ownership

• Take ownership of complete assembly cycle from material preparation to final packaging.
• Ensure completed assemblies are labelled, protected, and packed appropriately.
• Prepare products for transportation and field deployment.
• Follow ESD‑safe handling and packaging methods.
• Ensure packaging standards for sensitive electronics and rugged systems.

Skills Required

A. Technical Skills

• Wire harness assembly
• Precision crimping tools usage
• Soldering and rework skills
• Continuity testing
• Harness routing and protection
• Troubleshooting

B. Preferred Skills

• Defence / aerospace / automotive harness experience
• Reading electrical schematics and wiring diagrams
• Understanding of shielding, grounding, and EMI considerations
• Familiarity with ruggedised electronics manufacturing
• IPC standards knowledge (IPC‑A‑610 / IPC‑WHMA‑A‑620 preferred)

Desired Candidate Profile

• Diploma / ITI / B.Tech in Electrical, Electronics, Mechatronics, ECE, or related field
• 1–4 years of hands‑on experience in wire harnessing and electrical assembly
• Strong hand skills and attention to detail
• Comfortable working on prototypes and low‑volume production
• Ability to work independently with ownership mindset
• Willingness to support field trials and rapid product iterations