Wiring Harness Design Engineer
Confirmed on the employer's own hiring board on Oct 31, 2026. First seen by Alion on Oct 4, 2026. SEGULA Technologies scores A on the Alion truth index.
3D Wiring Harness Routing & Packaging: Develop and optimize 3D harness routing in NX (Preferred) / CATIA V5/V6 / 3DEXPERIENCE across all product zones, including components that move during motions. Define electrical bundle properties, bundle diameters, branch points, and service loops according to OEM packaging guidelines.
Schematic Development & Circuit Validation: Create, analyze, and validate 2D circuit diagrams and schematics using Siemens Capital (Capital Harness XC / CHS), Arcadia, or Mentor Graphics. Cross-verify schematic nets against Electronic Function Tables (EFT), vehicle architecture sheets, and L-Cable / EE data across critical subsystems (BCM, EMS, ABS, ADAS, Airbags).
Component, Retention & Protection Selection: Select appropriate automotive connectors, terminals, cavity plugs, relays, fuses, and grommets. Define retention hardware (clips, cable ties, brackets, standoffs) and protective coverings (corrugated tubes, braided sleeves, heat-shrink tubes, heat-shielding reflective wraps) based on environmental zone temperature classes, abrasion severity, and chemical exposure.
DMU Clearance & Dynamic Buckle Studies: Perform 3D DMU clash, clearance, and interference analysis against fixed components and the components that move during operation. Conduct dynamic buckle simulations and kinematic motion studies for harness flex zones across all Dynamic & Static conditions.
Supplier Data Export & Milestone Release: Generate CHS/Capital exports, CATPart/flattened models, and DFS/DFC change documentation. Prepare and release Drawing RFQs, TGA, VC, PPC, and TR05 milestone packs to harness suppliers; conduct PEI / peer drawing reviews and supplier DFM sign-offs.
Issue Tracking & Engineering Change Management: Process and resolve harness change requests received via JIRA / Ford internal change management systems. Lead cross-functional root-cause investigations for harness assembly, routing, or electrical packaging non-conformances.
Flexibility of Scope: This position is not limited to the above scope only; based on program needs, the resource may be required to perform other related electrical distribution systems (EDS) and process engineering activities.
Supporting physical wire harness prototyping, physical harness board manufacturing, or direct assembly line repair work at plant facilities.