Tesla

Makes electric cars, robotaxis and grid batteries

Wire Harness Process Engineer - Harness, Megapod

Manufacturing EngineeringConfirmed live in the last 24 hours

Full-timeBrookshire, TX, USANo salary listedIn-person

About the Job

Requirements

A degree in Engineering or equivalent experience.
At least 5 years of manufacturing process engineering experience, ideally with wire harness, cable assembly, or interconnect processes.
Working knowledge of IPC/WHMA-A-620.
Experience developing and maintaining process documentation, including work instructions, visual aids, standard operating procedures, control plans, and process failure mode and effects analyses.
Hands-on experience with tooling, fixtures, jigs, crimp applicators, automated wire processors, pull testing, crimp height measurement, and microsectioning.
Experience supporting new product introduction, prototype and first-article builds, production ramp-up, and Design for Manufacturability and Assembly reviews.
Skills in root-cause analysis, corrective and preventive action, statistical process control, yield and cycle-time analysis, and Lean/5S continuous-improvement projects with measurable results.
Ability to train and certify operators and inspectors on workmanship standards and process controls.
Proficiency with Microsoft Office, enterprise resource planning/material requirements planning systems, data analysis tools, and basic computer-aided design for fixtures.
Familiarity with additional quality standards such as AS9100, IATF 16949, ISO 9001, and IPC-A-610, and experience in automotive, aerospace, medical, or high-reliability environments.

Responsibilities

Develop, document, and maintain process flows, work instructions, visual aids, standard operating procedures, routers, and control plans that meet IPC/WHMA-A-620 requirements for wire preparation, crimping, soldering, splicing, insulation-displacement connectors, ultrasonic welding, connector and terminal insertion, routing, bundling, lacing, shielding, grounding, sleeving, heat-shrink, labeling, overmolding, potting, and testing.
Establish and qualify processes to achieve the specified product class, with appropriate inspection frequency and process indicators.
Specify, design, procure, and validate tooling, fixtures, jigs, crimp applicators, automated wire processors, and testers; perform crimp validation through pull testing, crimp height measurement, and microsectioning, as well as first-article inspections.
Support prototype builds, first-time builds, and production ramp-up; conduct Design for Manufacturability and Assembly reviews of drawings, schematics, wire lists, and bills of materials.
Lead root-cause analysis, process failure mode and effects analysis updates, and corrective and preventive action for defects such as nicked or broken strands, incomplete crimps, improper seating, routing violations, and test failures.
Train and certify operators and inspectors on IPC/WHMA-A-620 workmanship criteria, visual inspection, and process controls; maintain training records.
Analyze yield, cycle time, quality data, and statistical process control; drive Lean, 5S, and continuous-improvement projects to reduce cost, improve throughput, and eliminate defects.
Collaborate with Design Engineering, Quality, Supply Chain, and Production; review engineering change orders and implement process changes.
Integrate additional customer or industry requirements, including AS9100, ISO 9001, automotive, aerospace, and medical requirements, with IPC/WHMA-A-620.
Stay current with standard revisions, IPC-D-620 and related documents; participate in internal audits and customer and supplier assessments.

Desired Qualifications

IPC/WHMA-A-620 Certified Application Specialist or Certified Trainer credential is strongly preferred.
Minitab or equivalent data analysis tool experience is preferred.

Category	Manufacturing
Location	Brookshire, Texas
Requisition ID	285921
Type	Full-time

Job Description

The Wire Harness Process Engineer develops, implements, validates, and continuously improves manufacturing processes for cable and wire harness assemblies. The role ensures all processes and workmanship fully comply with IPC/WHMA-A-620 (Requirements and Acceptance for Cable and Wire Harness Assemblies), the industry-consensus standard that defines materials, methods, tests, and visual/dimensional acceptance criteria (Target, Acceptable, and Defect conditions) for crimped, soldered, and mechanically secured interconnections as well as related assembly operations. The engineer supports New Product Introduction (NPI), high-volume or high-reliability production (typically Class 2 or Class 3), quality, and cost/efficiency goals while maintaining process control, documentation, and operator competency to the latest revision of the standard (currently IPC/WHMA-A-620F).

Job Responsibilities

Develop, document, and maintain process flows, work instructions, visual aids, SOPs, routers, and control plans that meet IPC/WHMA-A-620 requirements for wire preparation (cutting, stripping, tinning), crimping (height, bellmouth, insulation support, conductor brush, pull-force), soldering, splicing, IDC, ultrasonic welding, connector/terminal insertion, routing/bundling/lacing, shielding/grounding, sleeving/heat-shrink, labeling, overmolding/potting, and testing
Establish and qualify processes to achieve the specified product class (Class 1 – General Electronic Products; Class 2 – Dedicated Service; Class 3 – High-Reliability) with appropriate inspection frequency and process indicators
Specify, design, procure, and validate tooling, fixtures, jigs, crimp applicators, automated wire processors, and testers; perform crimp validation (pull testing, crimp height, microsectioning) and first-article inspections
Support prototype builds, first-time builds, and production ramp-up; conduct Design for Manufacturability and Assembly (DFMA) reviews of drawings, schematics, wire lists, and BOMs
Lead root-cause analysis, PFMEA updates, and CAPA for defects (e.g., nicked/broken strands, incomplete crimps, improper seating, routing violations, test failures)
Train and certify operators and inspectors on IPC/WHMA-A-620 workmanship criteria, visual inspection, and process controls; maintain training records
Analyze yield, cycle time, quality data, and SPC; drive Lean, 5S, and continuous-improvement projects to reduce cost, improve throughput, and eliminate defects
Collaborate with Design Engineering, Quality, Supply Chain, and Production; review ECOs and implement process changes
Ensure additional customer or industry requirements (AS9100, ISO 9001, automotive, aerospace, medical, etc.) are integrated with IPC/WHMA-A-620
Stay current with standard revisions, IPC-D-620 (design companion), and related documents; participate in internal audits and customer/supplier assessments

Job Requirements

Degree in Engineering, or equivalent experience
5+ years of manufacturing process engineering experience, ideally with wire harness, cable assembly, or interconnect processes
Working knowledge of IPC/WHMA-A-620; IPC/WHMA-A-620 Certified Application Specialist (CIS) or Certified Trainer (CIT) strongly preferred
Proven experience developing and maintaining process documentation, including work instructions, visual aids, SOPs, control plans, and PFMEAs
Hands-on experience with tooling, fixtures, jigs, crimp applicators, automated wire processors, pull testing, crimp height measurement, and microsectioning
Experience supporting NPI, prototype/first-article builds, production ramp-up, and Design for Manufacturability and Assembly (DFMA) reviews
Strong skills in root-cause analysis, CAPA, SPC, yield/cycle-time analysis, and driving Lean/5S continuous-improvement projects with measurable results
Demonstrated ability to train and certify operators and inspectors on workmanship standards and process controls
Proficiency with Microsoft Office, ERP/MRP systems, data analysis tools (Minitab or equivalent preferred), and basic CAD for fixtures
Familiarity with additional quality standards (AS9100, IATF 16949, ISO 9001, IPC-A-610, etc.) and experience in automotive, aerospace, medical, or high-reliability environments

About the Company

Tesla

Makes electric cars, robotaxis and grid batteries

Tesla makes electric cars and batteries that store power for homes and utilities, and it develops self-driving software and humanoid robots. In 2023, its Model Y became the first electric vehicle to rank as the world's best-selling car. Buyers order the Model 3 sedan, Model Y SUV, or Cybertruck pickup directly from Tesla instead of through dealers, and they charge on its Supercharger fast-charging network. It also sells Megapack and Powerwall batteries, runs a robotaxi service, and charges drivers a monthly fee for self-driving software that still needs their supervision. Tesla was founded in 2003, with Elon Musk as its lead early investor and a recognized co-founder, and it is based in Austin, Texas.

Company size: 10,001+
Company stage: IPO
Headquarters: Austin, TX
Founded: 2003

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