Lead Aerospace Wire Harness Technician

Lead Aerospace Wire Harness Technician

Location:
Bohemia, NY
- On-Site

Build the capability behind mission-critical aerospace systems.

Are you ready to take a hands-on leadership role in building a new manufacturing capability from the ground up?

Dayton T. Brown, Inc., a recognized leader in engineering, testing, logistics, and mission‑critical military systems, is seeking an experienced Lead Wire Harness Technician to join our Technical Services Division.

This is a unique opportunity for a highly experienced aerospace wire harness professional to help establish and lead a new wire harness assembly operation supporting complex military and aerospace programs.

The successful candidate will play a key role in the initial stand‑up of the operation, including reviewing technical drawing packages, defining manufacturing processes, identifying and selecting required tooling and equipment, establishing production work areas, supporting material and tooling procurement, and developing the processes necessary to produce high‑quality aerospace wire harness assemblies.

Once the capability is established, this individual will serve as the technical and program lead for wire harness manufacturing activities while remaining hands‑on in the production environment. The candidate should be comfortable building and troubleshooting harness assemblies, training future technicians, interfacing Quality and Engineering personnel, supporting customer requirements, and providing technical leadership throughout the manufacturing process.

The ideal candidate has extensive experience manufacturing high‑reliability aerospace or defense cable and wire harness assemblies and possesses strong knowledge of the tooling, processes, workmanship requirements, inspection methods, and testing associated with complex military/aerospace harnesses.

This position requires strong organizational and communication skills and the ability to work independently while helping Dayton T. Brown establish a scalable wire harness manufacturing capability. The individual will work closely with Purchasing, Quality, Operations, Program Management, and customers as the operation grows.

There may be times when overtime is required as well as travel.

Job qualifications include:

• Demonstrated ability to interpret complex engineering drawings, wiring diagrams, wire lists, bills of material (BOMs), specifications, and manufacturing requirements.
• Strong working knowledge of IPC/WHMA-A-620 workmanship and inspection requirements.
• Experience working to SAE AS50881 or comparable aerospace wiring requirements.
• Extensive hands‑on experience with aerospace wire harness manufacturing processes including:
  • Wire cutting, stripping, preparation, and routing
  • Precision crimping and contact termination
  • Connector assembly and contact insertion/extraction
  • Shielding, overbraid, and EMI/RFI back shell termination
  • Solder sleeves and heat‑shrink components
  • Coaxial cable termination
  • Twinax and/or quadrax termination
  • Harness identification and labeling
  • Harness layout and build‑board/template development
• Demonstrated knowledge of crimp tooling, dies, turrets, positioners, insertion/extraction tools, and associated inspection/calibration requirements.
• Experience performing and/or overseeing electrical continuity, open/short, and miswire testing of completed harness assemblies.
• Experience with automated wire harness test equipment such as Cirris or equivalent is highly desirable.
• Experience with crimp pull testing and process validation.
• Ability to establish manufacturing processes, work instructions, travelers, tooling requirements, and inspection/test processes for new harness assemblies.
• Experience supporting material procurement, tooling selection, manufacturing planning, and production readiness…