Wiring Harness Maintenance Engineers

Overview

As an Automotive engineer, you will be part of the team who are transforming the future of mobility industry by developing solutions for autonomous vehicles, electric mobility, and digitalisation. Join us to help the global automotive giants to optimise performance and sustainability through continuous innovation. You will have the opportunity to work on projects that integrate the latest technologies to enhance vehicle safety, efficiency, and environmental impact.

Make a direct impact on creating safer, smarter, and greener transportation solutions that will define the automotive industry of tomorrow.

Expleo is the home of bold and reliable minds. With more than 50 years of experience in developing complex products, optimising manufacturing processes, and ensuring the quality of information systems, Expleo boasts an extensive global footprint, powered by 19,000 highly skilled experts delivering value in 30 countries.

Our efforts in creating a supportive and inclusive workplace in India have earned us some key recognitions:

• 'Great Place to Work' certification for building a supportive, engaging environment.
• 'Progressive Place to Work,' by ET Now, for our dedication to innovation and inclusive workplace policies.
• 'Best Organizations for Women,' by ET Now, for empowering women by providing equal opportunities, supporting professional development and promoting inclusive leadership.

Responsibilities

Ensure safe, reliable and cost-effective operation of wire harness manufacturing equipment through preventive, predictive and corrective maintenance. The role owns equipment availability, breakdown reduction, maintenance standards, spare-parts readiness, technical problem solving and continuous improvement across cutting, stripping, crimping, sealing, welding, assembly and electrical testing processes.

• Plan and execute preventive, predictive and corrective maintenance for automatic cut-and-strip machines, terminal crimping presses, seal insertion units, applicators, wire twisting equipment, ultrasonic/spot welding machines, taping and assembly aids, conveyor systems and electrical continuity/test boards.
• Lead breakdown response using structured fault diagnosis for PLCs, HMIs, servo drives, sensors, pneumatics, electrical panels, safety circuits and mechanical mechanisms; restore equipment safely and minimize production loss.
• Develop equipment maintenance standards, check sheets, lubrication plans, inspection frequencies, critical parameter limits and escalation criteria based on OEM recommendations and failure history.
• Track equipment performance using OEE, availability, MTBF, MTTR, breakdown hours, PM compliance, repeat failures and maintenance cost; review trends and implement focused countermeasures.
• Perform root cause analysis for chronic and high-impact failures using 5 Why, Ishikawa, Pareto and 8D methodology; verify corrective-action effectiveness and standardize learning across similar machines.
• Maintain process capability and machine condition for critical characteristics such as crimp height/width, pull force, conductor brush, insulation support, seal position, strip length, weld energy and electrical test accuracy.
• Coordinate planned maintenance with Production, Quality, Process Engineering, EHS, IT/OT and suppliers to protect safety, delivery and product quality.
• Control critical spares, min/max stock, repairable items, obsolescence risks and annual maintenance contracts; ensure traceability of high-value spares and calibration-sensitive components.
• Support new equipment installation, utility readiness, FAT/SAT, commissioning, machine capability, safety validation, handover documentation and ramp-up stabilization.
• Drive TPM, autonomous maintenance and kaizen activities; coach operators on basic checks, abnormality identification, cleaning, lubrication and first-level maintenance.
• Ensure compliance with lockout/tagout, electrical safety, machine guarding, permit-to-work, contractor safety, 5S and waste-disposal requirements.
• Maintain CMMS/GMAO records, work orders, failure codes, PM history, service reports, manuals, electrical drawings, PLC backups, spare lists and equipment lifecycle records.

Qualifications

B.E. OR Diploma 

Essential skills

• Hands-on troubleshooting of PLC-controlled automation; working knowledge of Siemens, Mitsubishi, Omron, Allen-Bradley or equivalent platforms is preferred.
• Proficiency in electrical controls, servo/VFD systems, industrial sensors, relays/contactors, safety relays, pneumatics, hydraulics, bearings, gearboxes and precision mechanisms.
• Practical knowledge of wire harness processes: cable cutting/stripping, terminal crimping, applicator setup, seal insertion, splice/welding, twisting, taping, routing, continuity testing and end-of-line validation.
• Ability to read electrical schematics, pneumatic diagrams, mechanical drawings, equipment manuals and spare-parts catalogues; ability to maintain version-controlled backups and documentation.
• Knowledge of IATF 16949 manufacturing controls, ISO 14001 and ISO 45001 practices, MSA/calibration interfaces, PFMEA, Control Plan, layered audits and change management.
• Working capability with CMMS/GMAO, Microsoft Excel and Power BI or equivalent tools for maintenance analysis, dashboards and action tracking.

Desired skills

• Lead technicians and contractors during routine work, shutdowns and emergencies with clear work allocation, safety control and escalation.
• Communicate effectively with Production and Quality teams, translating equipment issues into risk, containment, recovery plan and permanent action.
• Demonstrate ownership, disciplined follow-up, data-based decision-making, strong shop-floor presence and willingness to work across shifts.

Coach junior engineers and technicians; build skill matrices and structured training plans for electrical, mechanical and process-maintenance competencies

Experience

3-6 years if B.E. OR 6-8 years if DIPLOMA

Benefits

• Collaborative working environment – We stand shoulder to shoulder with our clients and our peers, developing solutions that create a sustainable today and tomorrow.
• Continuous learning - Our Learning & Leadership Development team has established a world-class learning ecosystem that enables you to acquire and develop the right skills by delivering a suite of accredited training courses.
• Global organisation - We provide solutions to leading brands from various sectors, giving you the opportunity to work with top-tier companies providing impactful solutions to our customers’ customers.