Manufacturing Specialist, Harnessing

Castelion; Torrance (CA); On-site; USD 90,000 - 120,000; Full time

Job summary

Castelion is seeking a Manufacturing Specialist to lead harness fabrication process development, supplier qualification, and transition from prototype to production. The role focuses on wiring harnesses, cable assemblies, interconnect systems, and related test plans within a defense manufacturing context.

The candidate will support both in-house and supplier fabrication activities, drive continuous improvement, and ensure on-time, zero-defect delivery of harness assemblies.

Qualifications

• Bachelor's degree in engineering (Mechanical, Electrical, Manufacturing or related).
• 3+ years in manufacturing engineering with wiring harness/cable assembly, fabrication and test.
• Excellent written and verbal communication skills.
• Authorized to work in the U.S. and comply with ITAR eligibility requirements.

Responsibilities

• Create and maintain harness assembly work instructions, BOM/MBOM, harness flows, test plans, and tooling specifications for prototype and production builds.
• Qualify and develop external harness fabrication partners; define quality/test criteria and prepare production readiness.
• Support DFM/DFT reviews, connector selection, routing, and supplier handoff readiness; facilitate risk analysis and manufacturing readiness reviews.
• Develop harness test procedures and systems for continuity, insulation resistance, hi-pot/functional tests, and data analysis.
• Drive continuous improvement, yield, throughput, and cost optimization using Lean/CI methodologies.

Skills

Hands-on process development

Written and verbal communication

Problem solving

Quality awareness

ITAR/compliance awareness

Education

Bachelor's degree in engineering

Job description

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

Why Castelion, Why Now

Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus, ownership, and excellence are decisive advantages - and we're building a world-class team to turn bold ideas into real capability.

This is a rare opportunity to join at an early stage, where you'll have significant ownership, collaborate with exceptional teammates, and make a direct, measurable impact on our mission and the future of the company - regardless of your function.

Manufacturing Specialist, Harnessing

Castelion is seeking a Manufacturing Engineer to lead the development and implementation of manufacturing processes for wiring harnesses, cable assemblies, interconnect systems, and associated test plans. This role will support both in-house and supplier fabrication and test activities as we transition designs from prototype to scaled production in support of next-generation defense systems.

Key Outcomes for 2026

• Establish In-House Harness Fabrication Capability – define, document, and implement procedures, tooling standards, work instructions, and process flows for harness fabrication and validation.
• Establish & Qualify a Supply Chain for Prototype and Production Harness Fabrication – identify, evaluate, and onboard supplier partners for harness fabrication and test that align with part complexity, lead time needs, and quality/risk requirements. Define supplier qualification criteria (capability matrices, certifications, workmanship standards, test coverage, inspection tools) and establish supplier audits, capability studies, and baseline process validations.
• Deliver All Harness Assemblies On-Time with Zero Defects – drive, track, and report build execution for all harnessing to meet development, test, and qualification milestones. Establish and enforce key quality checkpoints to detect and resolve assembly, continuity, or functional defects before delivery to integration.

Responsibilities

• Assembly & Test Procedure – create and maintain work instructions, bill of materials (BOM/MBOM), harness assembly flows, test plans, fixture/tooling specifications, and manufacturing process documentation for prototype and production harness builds.
• Supplier Development & Support – partner with supply chain to qualify and develop external harness fabrication partners, define quality/test criteria (continuity, insulation, functional, hi-pot), and support supplier readiness for production builds.
• Prototype to Production Transition – support design reviews with a focus on design for manufacturability (DFM), design for test (DFT), connector selection, harness routing, and supplier handoff readiness. Facilitate risk analysis and manufacturing readiness reviews (MRRs).
• Testing & Validation – develop and implement harness test procedures and systems for continuity, insulation resistance, high-pot/functional verification, environmental screening when required, and test data analysis.
• Continuous Improvement & Metrics – drive yield improvement, throughput gains, defect reduction, and cost optimization through Lean and CI methodologies.

Requirements & Qualifications

• Bachelors degree in mechanical, Electrical, Manufacturing, or related Engineering discipline.
• 3+ years of experience in manufacturing engineering with emphasis on wiring harness/cable assembly processes, fabrication, and test.
• Strong familiarity with harness standards (crimping, routing, strain relief techniques), electrical continuity/functional test methods, and assembly best practices.
• Hands-on experience developing manufacturing processes and work instructions for electromechanical hardware.
• Excellent written and verbal communication skills.
• Must be authorized to work in the U.S. and comply with ITAR eligibility requirements.

Leadership Qualities

• Bias to Action and Creative Problem Solving. Desire and experience questioning assumptions in ways that lead to break through ideas that are ultimately implemented. Successfully bring in applicable processes/concepts/materials from other industries to achieve efficiency gains. Ability to personally resolve minor issues in development without requiring significant support.
• High Commitment, High Initiative. A successful candidate will have a genuine passion for Castelion's mission and consistently look for ways to contribute to the company's technical goals and prevent hardware blockers. Ability to work in a fast paced, autonomously driven, and demanding atmosphere. Strong sense of accountability and integrity.
• Clear Communicator. Proactively communicates blockers. Trusted in previous roles to be voice of company with regulators, suppliers, gate keepers and customers. Capable of tactfully managing relationships with stakeholders to achieve company-desired outcomes without compromising relationships. Emails, IMs and verbal interactions are logical, drive clarity, and detailed enough to eliminate ambiguity.

Castelion offers a generous benefits package. Please refer to the bottom of our Careers page for more details.

Other Duties

Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.

Additional Eligibility Requirements

This position may require access to classified information or restricted U.S. Government sites, systems, or information, as determined by the Company and/or applicable U.S. Government requirements. If the position is so designated, your employment in the role may be contingent upon your ability to obtain and maintain the required U.S. Government security clearance or other government authorization, and to satisfy any citizenship or other eligibility requirements imposed by applicable law, regulation, executive order, or government contract requirements. You will be notified if and when such requirements apply.

Affirmative Action/EEO Statement

Castelion is an Equal Opportunity Employer. We are committed to providing equal employment opportunities to all applicants and employees without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, protected veteran status, or any other characteristic protected by applicable federal, state, or local law.

Castelion is committed to providing reasonable accommodations to qualified individuals with disabilities throughout the application and hiring process. If you require a reasonable accommodation to complete an application, participate in the interview process, or otherwise participate in the hiring process, please contact [e-mail]. Requests for accommodation will be considered on an individual basis and handled in accordance with applicable law.

Castelion is committed to fostering a workplace where employment decisions are based on qualifications, business needs, and the ability to perform the essential functions of the role, with or without reasonable accommodation.

EAR/ITAR Requirements

This position requires access to export-controlled information, and as such, employment (or hiring of a contractor) is contingent upon the candidate’s ability to access all applicable export-controlled information without additional export licensing being required by the Bureau of Industry and Security and/or the Directorate of Defense Trade Controls.