Wire Harness Designer

Job Title:

Lead Wiring Harness Design Engineer

The Lead Wiring Harness Design Engineer designs, develops, and releases complete high-voltage and low-voltage wiring harness systems for high-volume manufactured products. This role owns the full product lifecycle for harness design, from concept and schematics through 3D routing, prototyping, validation, and supplier coordination, while ensuring compliance with regulatory standards and supporting cross-functional teams in a Lean development environment.

• Design, develop, and release complete high-voltage and low-voltage wiring harness systems, including wire and cable gauge sizing, connector selection, terminal and crimp definitions, complex harness routing, and manufacturing considerations.
• Create and maintain logical wiring diagrams and schematics, detailed 2D harness manufacturing drawings, bills of materials (BOMs), and related engineering specifications.
• Complete and maintain the GEA wiring harness checklist to ensure design quality and compliance.
• Drive and guide the CAD team on 3D harness routing, packaging, clearance optimization, and thermal and vibration strain relief within a 3D CAD environment.
• Build and/or support prototype harness builds to validate feasibility, manufacturability, serviceability, and assembly methods.
• Coordinate harness fabrication with external suppliers, including defining and reviewing quality plans and managing first-piece qualification activities.
• Ensure wiring harnesses, connectors, and related components comply with UL requirements and other applicable regulatory standards.
• Drive connector and harness standardization across product lines to improve quality, reduce cost, and increase design reuse.
• Own FRACAS (Failure Reporting, Analysis, and Corrective Action System) investigations for wiring harness failures during design verification, reliability testing, and early field returns, and drive closure with robust corrective actions.
• Apply Six Sigma and reliability engineering methods to validate designs, identify root causes, and implement durable, data-driven solutions.
• Collaborate with cross-functional engineering and operations teams within a Lean product development process to ensure designs meet performance, cost, and manufacturability targets.
• Partner closely with Controls and Electrical Engineering teams to support product-level EMI/EMC testing, troubleshoot issues, and implement design changes as needed.
• Lead and contribute to DFMEAs (Design Failure Modes and Effects Analyses) for wiring harness systems to proactively identify and mitigate risk.
• Plan and manage wiring harness design activities and deliverables as part of broader project plans, ensuring milestones and deadlines are met.

• Bachelor’s degree in electrical engineering, mechanical engineering, or a related engineering field.
• Minimum of 7 years of engineering design experience on high-volume manufactured products.
• At least 5 years of dedicated experience designing wiring harnesses, including connector and terminal selection, wire insulation and derating calculations, and supplier qualification.
• Minimum of 5 years of experience using Creo Schematic or a similar electrical CAD tool for wiring harness design.
• Proven experience leading DFMEAs for complex electro-mechanical systems.
• Demonstrated project planning experience, including scheduling, prioritizing tasks, and coordinating with cross-functional teams.
• Strong analytical and problem-solving skills with a hands‑on approach to troubleshooting and validation.
• Experience ensuring designs meet regulatory requirements such as UL, FCC, or CE.
• Technical expertise in wiring harness design, wiring schematics, cable assembly, and electronics.
• Ability to collaborate effectively with CAD…