Coil and Core Assembler

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Full-Time Non-Exempt Manufacturing / Production, Tomball, TX

The Coil and Core Assembler is responsible for the assembly and integration of transformer coils and magnetic cores in accordance with engineering specifications, work orders, and quality standards. This role is central to the manufacturing of dry-type transformers and requires a skilled assembler who can handle precision components, read technical drawings, and consistently produce assemblies that meet dimensional accuracy and electrical performance requirements.

The Coil and Core Assembler works under the direction of the Production Supervisor and is expected to maintain a safe, organized, and efficient workspace at all times.

• Assemble wound transformer coils including the installation of insulation materials, spacers, lead extensions, and tap connections in accordance with engineering drawings and work instructions
• Position and secure primary and secondary coil assemblies accurately to ensure proper electrical clearances and mechanical fit
• Apply insulating materials including kraft paper, fiberglass, and other dielectric materials as specified in the design documentation
• Prepare coil leads and connections for terminal attachment in coordination with the terminal assembly team

• Stack and assemble silicon steel laminations to build transformer cores according to engineering specifications and lamination patterns
• Align, clamp, and secure core assemblies to ensure proper magnetic circuit geometry, minimal air gaps, and structural integrity
• Install core hardware including tie rods, clamps, yoke plates, and base frames per design requirements
• Handle and stage lamination materials carefully to prevent damage, burrs, or contamination that could affect core performance

• Insert and seat assembled coils onto the transformer core accurately, ensuring proper alignment, clearances, and insulation integrity
• Install blocking, bracing, and support structures to secure the coil and core assembly within the transformer frame or enclosure
• Complete final assembly steps including the installation of top yokes, clamping structures, and mounting hardware

• Read and interpret engineering drawings, assembly diagrams, lamination schedules, and work instructions accurately
• Apply knowledge of imperial measurement systems to verify component dimensions and assembly tolerances
• Identify and communicate discrepancies between specifications and physical components to the Production Supervisor or engineering team

• Inspect completed coil and core assemblies for dimensional accuracy, insulation integrity, proper clearances, and workmanship quality
• Use precision measuring tools to verify component placement, torque values, and assembly dimensions
• Identify, document, and report any nonconformances, defects, or quality concerns to the supervisor or quality assurance team promptly
• Maintain a high standard of workmanship and quality throughout all stages of the coil and core assembly process

• Operate hand tools, power tools, torque wrenches, lifting equipment, and other assembly tools safely and efficiently
• Use overhead cranes, hoists, or other material handling equipment to safely position heavy core and coil assemblies as required
• Maintain tools and equipment in good working condition and report any malfunctions or damage to the supervisor

• Maintain a clean, organized, and hazard-free workspace in compliance with 5S standards and company safety policies
• Follow all company safety procedures, PPE requirements, and rigging and lifting protocols when handling heavy transformer components
• Identify and immediately report unsafe conditions, equipment malfunctions, or potential hazards to the Production Supervisor
• Participate in required safety training and contribute to a culture of safety on the production floor

• Work collaboratively with coil winders,…