Lead Aerospace Wire Harness Technician

Dayton T. Brown, Inc.; Bohemia (NY); On-site; USD 110,000 - 140,000; Full time

Benefits offered by this job

Profit sharing

401K with company match

Medical, dental and vision insurance

Job summary

Dayton T. Brown, Inc. is seeking a Lead Wire Harness Technician to establish and lead a new aerospace wire harness manufacturing capability. The role requires hands-on leadership, review of technical drawings, and defining processes for complex harness assemblies.

Ideal candidates have extensive experience with MIL-spec harnesses, IPC/WHMA-A-620, and related inspection methods. Travel and overtime may be required as the program scales.

Qualifications

• Interpret complex engineering drawings, wiring diagrams, BOMs and specifications.
• Experience with aerospace harness requirements (SAE AS50881) and IPC/WHMA-A-620 standards.
• Ability to establish manufacturing workflows, travelers, tooling needs, and inspection/test processes for new harnesses.

Responsibilities

• Lead stand-up of a new wire harness manufacturing capability for aerospace programs.
• Review drawings, define processes, select tooling, and set up production areas.
• Produce high-quality harness assemblies and troubleshoot in production.
• Train technicians and interface with Quality, Engineering, Purchasing and customers.
• Provide technical leadership across manufacturing and testing activities.
• Oversee testing and verification of harness assemblies and process controls.
• Travel and overtime may be required.

Skills

Interpret complex drawings

Wiring diagrams

Electrical testing

Aerospace harness knowledge

Leadership/team lead

Education

IPC/WHMA-A-620 certification

IPC J-STD-001 certification

Tools

Crimp tooling

Tooling & equipment selection

Cirris or wire harness test equipment

Job description

Build the capability behind mission-critical aerospace systems.

Are you ready to take a hands-on leadership role in building a new manufacturing capability from the ground up?

Dayton T. Brown, Inc., a recognized leader in engineering, testing, logistics, and mission-critical military systems, is seeking an experienced Lead Wire Harness Technician to join our Technical Services Division.

This is a unique opportunity for a highly experienced aerospace wire harness professional to help establish and lead a new wire harness assembly operation supporting complex military and aerospace programs.

The successful candidate will play a key role in the initial stand-up of the operation, including reviewing technical drawing packages, defining manufacturing processes, identifying and selecting required tooling and equipment, establishing production work areas, supporting material and tooling procurement, and developing the processes necessary to produce high-quality aerospace wire harness assemblies.

Once the capability is established, this individual will serve as the technical and program lead for wire harness manufacturing activities while remaining hands-on in the production environment. The candidate should be comfortable building and troubleshooting harness assemblies, training future technicians, interfacing Quality and Engineering personnel, supporting customer requirements, and providing technical leadership throughout the manufacturing process.

The ideal candidate has extensive experience manufacturing high-reliability aerospace or defense cable and wire harness assemblies and possesses strong knowledge of the tooling, processes, workmanship requirements, inspection methods, and testing associated with complex military/aerospace harnesses.

This position requires strong organizational and communication skills and the ability to work independently while helping Dayton T. Brown establish a scalable wire harness manufacturing capability. The individual will work closely with Purchasing, Quality, Operations, Program Management, and customers as the operation grows.

There may be times when overtime is required as well as travel.

Job qualifications include:

• Demonstrated ability to interpret complex engineering drawings, wiring diagrams, wire lists, bills of material (BOMs), specifications, and manufacturing requirements.


• Strong working knowledge of IPC/WHMA-A-620 workmanship and inspection requirements.


• Experience working to SAE AS50881 or comparable aerospace wiring requirements.


• Extensive hands-on experience with aerospace wire harness manufacturing processes including:


• Wire cutting, stripping, preparation, and routing


• Precision crimping and contact termination


• Connector assembly and contact insertion/extraction


• Shielding, overbraid, and EMI/RFI back shell termination


• Solder sleeves and heat-shrink components


• Twinax and/or quadrax termination


• Harness identification and labeling


• Harness layout and build-board/template development


• Demonstrated knowledge of crimp tooling, dies, turrets, positioners, insertion/extraction tools, and associated inspection/calibration requirements.


• Experience performing and/or overseeing electrical continuity, open/short, and miswire testing of completed harness assemblies.


• Experience with automated wire harness test equipment such as Cirris or equivalent is highly desirable.


• Experience with crimp pull testing and process validation.


• Ability to establish manufacturing processes, work instructions, travelers, tooling requirements, and inspection/test processes for new harness assemblies.


• Experience supporting material procurement, tooling selection, manufacturing planning, and production readiness activities.


• Ability to troubleshoot manufacturing issues and provide hands-on technical directions to other technicians.


• Strong communication skills with the ability to interact effectively with internal teams and external customers.


• Experience leading technicians, manufacturing teams, or aerospace production programs is highly desirable.


• Experience with military aircraft wiring systems, MIL-spec connectors, MIL-STD-1553 data bus assemblies, and other defense/aerospace interconnect systems is highly desirable.


• Demonstrated experience working with Microsoft Office applications.


• Ability to work in an on-site manufacturing environment.

REQUIRED Qualifications:

• Minimum 10+ years of direct hands-on experience manufacturing complex aerospace, defense, or other high-reliability cable and wire harness assemblies.


• IPC/WHMA-A-620 certification.


• IPC J-STD-001 certification.


• Ability to determine appropriate manufacturing tooling and equipment based upon engineering drawings, component requirements, and manufacturer specifications.

As a Dayton T. Brown employee, you can expect a fun working environment that provides security and career advancement and so much more such as:

• A stable, successful organization


• Innovative work environment


• Private medical, vision and dental insurance


• Profit sharing, 401K with company match


• Work/Life balance and family values

Dayton T. Brown, Inc. is an equal opportunity employer - Veterans and Disabled