Assistant Manager - Cable Harness Production Engineering

ZAMA Precision Industry Manufacturing Philippines, Inc.; Santo Tomas; On-site; PHP 600,000 - 1,000,000; Full time

Job summary

ZAMA Precision Industry Manufacturing Philippines, Inc. seeks an experienced Production Engineering Lead for Cable Harness to drive safe, stable, and cost-efficient manufacturing from wire prep to final inspection.

You will own process design, validation, control, and optimization across cutting, crimping, joining, routing, and testing, lead root-cause analyses, supervise teams, and coordinate with maintenance, quality, and tooling to ensure OEE targets and continuous improvements.

Qualifications

• Bachelor's degree in engineering field required.
• 5–8 years manufacturing or production engineering experience, preferably 3+ years in Cable Harness or automotive wiring.
• 2–3 years supervisory or engineering leadership experience.
• Demonstrated experience leading NPI, process validation, and cross-functional improvement projects.
• Strong knowledge of Cable Harness manufacturing processes and related testing and inspection.

Responsibilities

• Lead daily engineering support for Cable Harness production and drive containment, troubleshooting, and restoration of processes.
• Own design, validation, control, and optimization for wire cutting/stripping, crimping, twisting, splicing, routing, assembly, and testing.
• Establish standard cycle time, routing, line balancing, workforce standards, and equipment requirements.
• Lead root cause analyses and corrective actions for process defects and testing failures.
• Coordinate with Maintenance, Quality, Tooling, and other functions on tooling, validation, and process control.
• Define critical process controls and monitor parameters like crimp height, pull-force, and strip length.
• Develop and maintain Process Flow, PFMEA, Control Plan, Work Instructions, and change documentation.
• Lead product/process changes, run-at-rate, validation, and capability studies.
• Monitor OEE, uptime, throughput, scrap, and first-pass yield; drive cost-reduction projects.

Skills

Leadership experience

NPI experience

Process validation

Troubleshooting

Cross-functional

Cable Harness

Lean manufacturing

Project management

Data-driven decisions

Strong communication

Education

Bachelor's degree in industrial, Mechanical, Electrical, Electronics, Manufacturing Engineering, or related field

Job description

Main goal of job

• Lead Cable Harness production engineering to achieve safe, stable, capable, and cost-effective manufacturing processes from wire preparation through final electrical inspection.

• Ensure production readiness, process control, and technical response for cutting, stripping, crimping, twisting, splicing, sub-assembly, routing, taping, final assembly, and testing operations.

• Drive productivity, quality, capacity, localization, and cost-reduction improvements while meeting customer, drawing, safety, and quality-system requirements.

Specific Duties and Responsibilities

• Lead daily engineering support for Cable Harness production and ensure timely containment, troubleshooting, and restoration of affected processes.

• Own process design, validation, control, and optimization for wire cutting and stripping, crimping, twisting, splicing, terminal insertion, routing, taping, assembly, continuity testing, and visual inspection.

• Establish and maintain standard cycle time, routing, line balancing, manpower standards, workstation layout, tooling requirements, machine parameters, and process capacity.

• Lead root cause analysis and corrective and preventive actions for process defects such as crimp nonconformity, terminal damage or push-out, wrong wire or cavity insertion, exposed conductor, insulation damage, incorrect routing, and electrical test failures.

• Ensure control and validation of applicators, crimping tools, cutting and stripping equipment, test fixtures, poka-yoke devices, jigs, and inspection equipment in coordination with Maintenance, Quality, and Tooling.

• Define and monitor critical process controls, including crimp height and width, pull-force results, strip length, conductor and insulation position, splice quality, machine parameters, and electrical test limits.

• Develop and maintain Process Flow, PFMEA, Control Plan, Work Instructions, parameter sheets, setup standards, inspection criteria, and engineering change documentation.

• Lead product and process changes, sample builds, run-at-rate, process validation, capability studies, and production line readiness.

• Monitor OEE, productivity, UPH, cycle time, downtime, scrap, rework, first-pass yield, process capability, and engineering action closure.

• Drive line balancing, level loading, changeover reduction, mistake-proofing, automation, material utilization, and cost-reduction projects based on verified operational data.

• Coordinate with Production, Quality, Planning, Maintenance, Tooling, Purchasing, SQE, Logistics, and Product Engineering on technical issues and production readiness.

• Develop Process Engineers and Technicians through clear ownership, technical coaching, structured problem solving, and regular performance follow-up.

• Ensure compliance with EHS, quality, change-control, traceability, customer, and company requirements.

• Provide Production Engineering readiness approval for new products, transferred processes, equipment installations, engineering changes, and significant process modifications based on completed validation, capacity confirmation, tooling readiness, documentation, training, quality controls, and open-risk disposition.

• Exercise authority to stop or recommend stopping unsafe, unstable, or nonconforming processes; initiate containment; assign engineering resources; and elevate unresolved risks affecting safety, quality, delivery, capacity, cost, customer commitments, or project timing.

• Establish and coordinate qualification, condition monitoring, preventive maintenance, calibration, spare strategy, and replacement planning for critical machines, applicators, tools, test fixtures, jigs, and measurement equipment.

• Ensure critical processes are validated and statistically controlled, with documented containment and improvement plans when required process capability or stability is not achieved.

• Conduct or support layered process audits and engineering compliance reviews covering approved parameters, Work Instructions, Control Plans, tooling condition, traceability, and change-control requirements.

• Ensure technical documents are reviewed, approved, released, implemented, and withdrawn through the applicable document-control system, with obsolete revisions removed from production use.

• Establish technical training and qualification criteria for operators, setup personnel, technicians, and inspectors handling critical Cable Harness processes, in coordination with Production and Quality.

• Manage engineering manpower, competency development, succession planning, performance reviews, and technical qualification to ensure adequate support for serial production, projects, and continuous improvement.
  

Qualifications

• Bachelor's degree in industrial, Mechanical, Electrical, Electronics, Manufacturing Engineering, or a related engineering field.

• Minimum 5 to 8 years of experience in manufacturing or production engineering, preferably with at least 3 years in Cable Harness, automotive wiring, electrical assembly, or a comparable high-mix assembly environment.

• At least 2 to 3 years in a supervisory or engineering leadership role.

• Demonstrated experience leading NPI, process validation, production troubleshooting, and cross-functional improvement projects.

• Strong knowledge of Cable Harness manufacturing processes, including cutting, stripping, crimping, twisting, splicing, terminal insertion, routing, taping, assembly, and electrical testing.

• Working knowledge of crimp validation methods, including crimp height and width measurement, pull-force testing, cross-section analysis, and applicator setup control.

• Proficiency in Process Flow, PFMEA, Control Plan, Work Instructions, capability studies, MSA, SPC, 8D, 5 Why, and Ishikawa analysis.

• Experience with OEE, cycle-time analysis, routing standards, line balancing, capacity planning, downtime reduction, yield, scrap, and cost-reduction management.

• Knowledge of engineering change control, traceability, mistake-proofing, layered process controls, and customer-specific quality requirements.

• Ability to interpret product drawings, wiring diagrams, connector and terminal specifications, bills of materials, and process specifications.

• Familiarity with Lean Manufacturing, Kaizen, standard work, 5S, SMED, TPM, and project management.

• Proven leadership, people development, delegation, and performance-management skills.

• Strong project management, prioritization, risk management, and organizational skills.

• Ability to make timely, data-based decisions and manage multiple production-critical priorities.

• Strong cross-functional communication, escalation, stakeholder management, and conflict-resolution skills.

• Demonstrated accountability for technical standards, action closure, and sustainable results.

• Strong communication skills.