Lead Wiring Harness Engineer - HV/LV Systems

Actalent; Louisville (KY); On-site; USD 110,000 - 140,000; Full time

Benefits offered by this job

Medical, dental & vision

401(k) Retirement Plan

Life Insurance

Job summary

Actalent in Louisville, KY invites a Lead Wiring Harness Design Engineer to own the full lifecycle of harness development for high-volume products. You will design, validate, and release wiring harness systems, advise on 3D routing, select connectors, and coordinate with suppliers and cross-functional teams in a Lean environment.

Responsibilities include leading DFMEAs, EMI/EMC collaboration with controls and electrical engineering, and driving standardization to improve quality and reduce cost

Qualifications

• Bachelor’s degree in electrical engineering, mechanical engineering, or a related field.
• Minimum of 7 years of engineering design experience on high-volume manufactured products.
• At least 5 years of dedicated experience designing wiring harnesses, including connector and terminal selection, wire insulation and derating calculations, and supplier qualification.
• Minimum of 5 years of experience using Creo Schematic or a similar electrical CAD tool for wiring harness design.
• Proven experience leading DFMEAs for complex electro-mechanical systems.
• Demonstrated project planning experience, including scheduling, prioritizing tasks, and coordinating with cross-functional teams.
• Strong analytical and problem-solving skills with a hands‑on approach to troubleshooting and validation.
• Experience ensuring designs meet regulatory requirements such as UL, FCC, or CE.
• Technical expertise in wiring harness design, wiring schematics, cable assembly, and electronics.
• Ability to collaborate effectively with CAD teams, controls engineers, and operations personnel in a Lean product development environment.

Responsibilities

• Design, develop, and release complete high-voltage and low-voltage wiring harness systems, including wire and cable gauge sizing, connector selection, terminal and crimp definitions, complex harness routing, and manufacturing considerations.
• Create and maintain logical wiring diagrams and schematics, detailed 2D harness manufacturing drawings, bills of materials (BOMs), and related engineering specifications.
• Complete and maintain the GEA wiring harness checklist to ensure design quality and compliance.
• Drive and guide the CAD team on 3D harness routing, packaging, clearance optimization, and thermal and vibration strain relief within a 3D CAD environment.
• Build and/or support prototype harness builds to validate feasibility, manufacturability, serviceability, and assembly methods.
• Coordinate harness fabrication with external suppliers, including defining and reviewing quality plans and managing first-piece qualification activities.
• Ensure wiring harnesses, connectors, and related components comply with UL requirements and other applicable regulatory standards.
• Drive connector and harness standardization across product lines to improve quality, reduce cost, and increase design reuse.
• Own FRACAS investigations for wiring harness failures during design verification, reliability testing, and early field returns, and drive closure with robust corrective actions.
• Apply Six Sigma and reliability engineering methods to validate designs, identify root causes, and implement durable, data-driven solutions.
• Collaborate with cross-functional engineering and operations teams within a Lean product development process to ensure designs meet performance, cost, and manufacturability targets.
• Partner closely with Controls and Electrical Engineering teams to support product-level EMI/EMC testing, troubleshoot issues, and implement design changes as needed.
• Lead and contribute to DFMEAs for wiring harness systems to proactively identify and mitigate risk.
• Plan and manage wiring harness design activities and deliverables as part of broader project plans, ensuring milestones and deadlines are met.

Skills

7+ years engineering design

5+ years wiring harness design

Creo Schematic

DFMEA leadership

Regulatory knowledge UL FCC CE

Education

Bachelor’s degree in Electrical/Mechanical Engineering

Tools

Creo Schematic

3D CAD

Job description

Actalent in Louisville, KY invites a Lead Wiring Harness Design Engineer to own the full lifecycle of harness development for high-volume products. You will design, validate, and release wiring harness systems, advise on 3D routing, select connectors, and coordinate with suppliers and cross-functional teams in a Lean environment.

Responsibilities include leading DFMEAs, EMI/EMC collaboration with controls and electrical engineering, and driving standardization to improve quality and reduce cost