Process Engineer – Cable & Wire Harness Manufacturing

The Process Engineer is responsible for developing, implementing, and continuously improving manufacturing processes to support cable and wire harness production operations. The role focuses on enhancing productivity, product quality, process capability, and operational efficiency while ensuring compliance with customer, quality, and regulatory requirements.

This position works closely with Production, Quality, Maintenance, Supply Chain, and Engineering teams to support new product introductions, troubleshoot manufacturing issues, optimize production lines, and drive continuous improvement initiatives across the facility.

The ideal candidate possesses strong experience in manufacturing engineering, process optimization, lean methodologies, and production support within electronics, automotive, cable assembly, wire harness, or precision manufacturing environments.

Key Responsibilities:

Manufacturing Process Development

• Develop, implement, validate, and optimize manufacturing processes for cable and wire harness production.
• Establish standard operating procedures, work instructions, process flow diagrams, and manufacturing documentation.
• Support New Product Introduction (NPI) activities, including process development, tooling requirements, pilot builds, and production readiness.
• Evaluate manufacturing methods and recommend improvements to increase productivity, quality, and cost efficiency.
• Conduct process validation activities to ensure stable and repeatable manufacturing operations.

Production Support & Troubleshooting

• Provide day-to-day engineering support to production operations by resolving process-related issues and minimizing downtime.
• Investigate manufacturing defects, equipment issues, and process deviations using structured root cause analysis methodologies.
• Implement corrective and preventive actions (CAPA) to improve process performance and reduce recurring issues.
• Support line balancing activities to optimize manpower utilization and production output.
• Collaborate with Maintenance teams on equipment qualification, preventive maintenance planning, and troubleshooting activities.

Continuous Improvement

• Drive Lean Manufacturing and Continuous Improvement initiatives focused on waste reduction, productivity enhancement, cycle time reduction, and yield improvement.
• Monitor and analyze manufacturing performance indicators such as productivity, scrap rates, downtime, first-pass yield, and overall equipment effectiveness (OEE).
• Lead process improvement projects utilizing Lean, Six Sigma, Kaizen, and other problem-solving methodologies.
• Identify automation opportunities and support implementation of process enhancements to improve operational efficiency.

Quality & Compliance

• Prepare and maintain PFMEA, Control Plans, Process Flow Charts, and related manufacturing documentation.
• Ensure manufacturing processes comply with customer specifications, quality standards, and regulatory requirements.
• Support APQP, PPAP, process audits, and customer audit activities as required.
• Partner with Quality teams to improve process capability and reduce product defects.
• Participate in risk assessments and process reviews to ensure robust manufacturing controls.

Cross-Functional Collaboration

• Work closely with Production, Quality Assurance, Supply Chain, Maintenance, and Engineering teams to support operational objectives.
• Provide technical guidance and training to production personnel regarding process changes and best practices.
• Support engineering projects, capacity planning, and production expansion initiatives.

Qualifications:

• Bachelor's Degree in Mechanical Engineering, Industrial Engineering, Electrical Engineering, Manufacturing Engineering, or a related field.
• Minimum of 3 years of experience in Manufacturing Engineering, Process Engineering, or Production Engineering within a manufacturing environment.
• Experience in cable assembly, wire harness manufacturing, automotive, electronics, semiconductor, or precision manufacturing industries is highly preferred.
• Strong knowledge of manufacturing process development, production support, and process optimization.
• Experience with PFMEA, Control Plans, APQP, PPAP, Process Validation, and Root Cause Analysis methodologies.
• Familiarity with Lean Manufacturing, Six Sigma, Kaizen, and Continuous Improvement tools.
• Experience conducting line balancing, productivity analysis, and capacity improvement initiatives.
• Knowledge of ERP systems such as SAP is advantageous.
• Proficient in Microsoft Office applications and engineering documentation.
• Strong analytical, problem-solving, communication, and project coordination skills.

Preferred Qualifications:

• Licensed Mechanical Engineer, Electrical Engineer, or equivalent professional certification.
• Experience in wire harness manufacturing or automotive manufacturing environments.
• Exposure to ISO 9001, IATF 16949, and customer-specific quality requirements.
• Experience supporting automation, equipment improvement, or industrial engineering projects.
• Lean Six Sigma Green Belt or equivalent continuous improvement certification is an advantage.