Defense​/Automotive Wiring Harness NPD​/Production ENgineer

NPD PRODUCTION ENGINEER DEFENSE AUTOMOTIVE WIRING HARNESS

Department Engineering Manufacturing

Function NPD Industrialization Production Engineering

Industry Defense Automotive Wiring Harness

Location Jubail Saudi Arabia

Experience 4 8 Years

Preferred Job Purpose Responsible for the complete New Product Development NPD prototype development industrialization and production engineering of Defense and Automotive Wiring Harnesses starting from customer drawings BOM sample through prototype approval and serial production The engineer shall ensure that products are manufactured according to customer drawings applicable IPC WHMA-A-620 MIL automotive IATF APQP and PPAP requirements with focus on quality traceability productivity and delivery

• NPD Prototype Development Study customer drawings electrical schematics BOMs specifications and samples Develop complete wiring harnesses from drawing schematic or physical sample reverse engineering
  Prepare BOM From-To list cutting list wire list connector tables splice details and manufacturing drawings Select correct wires cables connectors contacts terminals seals backshells sleeves braids heat-shrink products and protection materials Manufacture and validate prototype First Article harnesses Coordinate technical clarification and prototype approval with customers Manage engineering changes drawing revisions and configuration control Convert approved prototype designs into serial-production processes
• Defense Wiring Harness Engineering Work with MIL-spec wires cables connectors and accessories Practical knowledge of circular military connectors particularly MIL-DTL-38999 and similar connector families Knowledge of MIL backshells contacts sealing plugs shielding and grounding arrangements Understand shield termination EMI EMC protection cable braiding and grounding requirements Define processes for crimping soldering splicing shielding braiding heat shrinking and connector assembly Ensure workmanship compliance with IPC WHMA-A-620 requirements Support First Article Inspection and customer defense quality inspections Maintain component and process traceability
• Automotive Wiring Harness Engineering Develop automotive LV wiring harnesses and associated subassemblies Knowledge of automotive connectors terminals seals clips grommets convoluted tubes tapes and protective sleeves Support APQP and PPAP activities Prepare review Process Flow Diagram PFMEA Control Plan Work Instructions Inspection Standards MSA Process Capability Studies Participate in design and process reviews Support customer-specific automotive quality requirements Knowledge of IATF 16949 requirements preferred
• Production Engineering Establish complete manufacturing processes for new wiring harnesses Develop production routing and assembly sequences Design develop harness boards fixtures and Poka-Yoke systems Select cutting stripping crimping and assembly tooling Set machine parameters and process specifications Conduct time studies and establish standard cycle times Calculate manpower and production capacity Balance production lines and workstations Support production during initial batches and mass production Improve FPY productivity and output
• Crimping Special Processes Strong practical knowledge required in Automatic semi-automatic wire cutting and stripping Terminal crimping Crimp height measurement Pull-force testing Crimp cross-section analysis Contact insertion extraction Soldering Ultrasonic wire splicing Heat-shrink processing Shield termination Cable braiding Harness taping and wrapping Connector assembly Potting sealing where applicable
• Testing Validation Define and support 100 continuity testing Open short circuit testing Insulation Resistance IR Hi-Pot Dielectric testing Resistance and voltage-drop testing Functional testing Connector pin verification Pull-force testing First Article Inspection Analyze test failures and implement corrective actions
• Quality Problem Solving Investigate internal and customer quality issues Perform Root Cause Analysis using 5-Why Fishbone 8D and CAPA methodologies Implement corrective and preventive actions Reduce rejection rework and customer complaints Participate in internal customer and certification audits Ensure compliance with approved manufacturing processes

Mandatory/Preferred Standards Knowledge Candidate should have exposure to:

• IPC/WHMA-A-620
• MIL-DTL-38999
• MIL-spec wiring and interconnection practices
• IATF 16949
• APQP