Process Engineer - Cable Harnessing
Confirmed on the employer's own hiring board on Oct 21, 2026. First seen by Alion on Oct 14, 2026.
Roles & Responsibilities :
Process Development - Develop and establish efficient manufacturing processes for cable cutting, stripping, crimping, terminal insertion, routing, taping, sleeving and final assembly.
Process Validation - Conduct trials, first-piece validation and process capability studies before releasing processes for mass production.
Work Instructions & Documentation - Prepare and maintain SOPs, Work Instructions, Process Flow, PFMEA, Control Plan and standard operating parameters.
Crimping Process Control - Establish and monitor crimp height, crimp width, pull-force and applicator parameters to ensure consistent termination quality.
Cycle Time & Line Balancing - Conduct time studies, establish standard cycle times and optimize workstation and manpower allocation.
Jig, Fixture & Tooling Development - Design and implement harness boards, fixtures, templates, poka-yoke devices and special tools to improve assembly accuracy and productivity.
Quality Improvement - Analyze process defects, conduct RCA/5 Why/8D and implement corrective and preventive actions to achieve Zero Defect.
Electrical Test Process - Develop and optimize continuity, open/short, Hi-Pot, insulation resistance and functional testing processes.
NPI & New Product Introduction - Support prototype, pilot and mass-production builds, including process trials, validation and production ramp-up.
Engineering Change Management - Implement drawing, BOM, specification and process changes through proper ECN/ECR control.
Poka-Yoke & Error Proofing - Identify potential assembly errors and implement mechanical, electrical and software-based error-proofing solutions.
Productivity Improvement - Drive cycle-time reduction, manpower optimization, UPH improvement, yield improvement and manufacturing cost reduction.
Lean & Continuous Improvement - Implement 5S, Kaizen, VSM, waste elimination and other Lean Manufacturing initiatives.
Machine & Tooling Readiness - Coordinate with Maintenance and suppliers for machine setup, preventive maintenance, calibration and tooling availability.
Cross-Functional Support - Work closely with Production, Quality, SCM, Maintenance, NPI and Design Engineering teams to resolve process issues and ensure stable mass production.