Roles & Responsibilities

- Program, set up, and operate automatic wire processing machines for cutting, stripping, crimping, sealing, and marking.
- Develop and validate cable harness manufacturing processes for recent product introduction (NPI) and mass production.
- Select and qualify applicators, crimp tools, wire guides, and terminals based on customer specifications.
- Optimize machine parameters such as strip length, crimp height, pull force, seal position, and wire length.
- Perform first-off approval and process validation before releasing production.
- Conduct crimp cross-section analysis, crimp height measurement, pull force testing, and visual inspection as per IPC/WHMA-A-620 standards.
- Troubleshoot machine alarms, feeding issues, crimp defects, and wire processing abnormalities to minimize downtime.
- Plan and execute preventive maintenance, calibration, and tooling replacement for Komax machines.
- Prepare and maintain machine setup sheets, work instructions,



process parameters, and validation records.
- Support engineering builds, pilot production, and production ramp-up while achieving customer delivery schedules.
- Analyze production data and improve OEE, cycle time, machine utilization, and Overall Equipment Effectiveness.
- Coordinate with Quality, Production, Maintenance, SCM, and suppliers to resolve cable harness manufacturing issues.
- Implement engineering changes (ECN/ECR), validate new terminals, wires, connectors, and applicators.
- Train operators and technicians on Komax machine operation, troubleshooting, safety, and quality requirements.
- Drive continuous improvement through Lean Manufacturing, 5S, Poka-Yoke, scrap reduction, and defect prevention to achieve FPY, productivity, and customer quality targets.

📌 Assistant Engineer - Cable Harnessing (Tamil Nadu)
🏢 Larsen u0026 Toubro
📍 Tamil Nadu