JOB DESCRIPTION – WIRING HARNESS IN-PROCESS QUALITY ENGINEER
Department: Quality
Function: Wiring Harness – Automotive, Home Appliances & Toy/Electric Ride-On Products
Reporting To: Quality Head / Plant Head
Employment Type: Full-Time
Job Level: Engineer / Supervisor – In-Process Quality
1. JOB PURPOSE
The Wiring Harness In-Process Quality Engineer will be responsible for maintaining and improving quality during all stages of wiring harness production.
The primary objective is to:
Prevent defects at source rather than finding them during final inspection or after customer complaint.
The engineer will continuously monitor production processes, operators and contractors to ensure that every wiring harness is manufactured according to:
- Approved drawing
- BOM
- Master sample
- Control Plan
- Work Instructions
- Customer specifications
- Defined quality standards
The engineer will have authority to stop production and hold material whenever a serious quality issue is identified.
2. KEY RESPONSIBILITIESA. LINE START-UP & FIRST-PIECE APPROVAL
Before starting bulk production, verify:
- Correct customer and part number
- Latest drawing/revision
- Approved BOM
- Correct master sample
- Correct wire type
- Correct wire size/gauge
- Correct wire colour
- Correct wire length
- Correct terminal
- Correct connector
- Correct seal
- Correct sleeve
- Correct tape
- Correct clips/accessories
- Correct fuse/switch/LED, wherever applicable
- Correct crimping applicator/tool
- Correct assembly board/jig
Approve and record the first piece / first-off sample before allowing bulk production.
No bulk production should start without first-piece approval.
3. WIRE CUTTING & STRIPPING QUALITY
Regularly check:
- Wire specification
- Wire size
- Wire colour
- Cutting length
- Stripping length
- Conductor condition
- Cut/damaged strands
- Insulation damage
- Incorrect or incomplete stripping
- Wire identification/marking, where applicable
Ensure machine settings are correct and inspection frequency is followed.
4. CRIMPING QUALITY CONTROL
Crimping is one of the most critical responsibilities of this position.
Check:
- Correct wire-terminal combination
- Correct applicator/tool
- Crimp height
- Crimp width, where applicable
- Conductor crimp
- Insulation crimp
- Bell mouth
- Brush length
- Cut-off tab
- Terminal deformation
- Damaged/missing strands
- Wire position inside terminal
- Insulation position
- Terminal locking condition
- Double wire crimp, where applicable
Ensure crimp measurements are performed at defined frequency.
5. PULL-FORCE / PULL-TEST CONTROL
- Conduct/verify pull-force testing as per defined standard.
- Ensure correct pull-force requirement according to wire size and terminal.
- Maintain pull-test records.
- Stop crimping operation if pull-force result is below specification.
- Identify and segregate production made since the last OK check.
- Correct crimping condition before restarting production.
6. TERMINAL & CONNECTOR ASSEMBLY
Check:
- Correct terminal
- Correct connector
- Correct cavity
- Correct wire colour in cavity
- Terminal fully inserted
- Terminal locking
- Secondary lock, where applicable
- Connector orientation
- Seal position
- No bent/damaged terminals
- No terminal push-back
- No loose terminals
Special attention should be given to preventing wrong cavity and cross-wiring defects.
7. HARNESS ASSEMBLY & ROUTING INSPECTION
During assembly, verify:
- Overall harness length
- Branch lengths
- Branch direction
- Wire routing
- Connector position
- Connector orientation
- Tape position
- Tape wrapping quality
- Sleeve length and position
- Heat-shrink position
- Clip/clamp position
- Fuse/fuse-holder position
- Switch position
- LED position and polarity
- Labels/markings
- Customer-specific accessories
- Overall workmanship
Harness should match the approved drawing and master sample.
8. ELECTRICAL & FUNCTIONAL TESTING
Ensure required harnesses are properly tested for:
- Continuity
- Open circuit
- Short circuit
- Cross wiring
- Wrong cavity
- Missing connection
- Polarity
- Connector pin position
Where applicable, verify:
- Switch operation
- LED operation
- Fuse operation/installation
- Battery connector polarity
- Electrical sub-assembly functionality
Ensure electrical testers and checking fixtures are functioning correctly.
9. PATROL / IN-PROCESS INSPECTION
Conduct regular patrol inspections of all running wiring harness lines.
Inspection should cover:
Cutting → Stripping → Crimping → Connector Insertion → Sub-Assembly → Harness Board → Taping/Sleeving → Electrical Testing → Final Line Output
Inspection frequency should be followed as defined in the Control Plan/work instructions.
The engineer should spend the majority of working time on the production floor, not in the quality office.
10. DEFECT & NON-CONFORMING MATERIAL CONTROL
Whenever a defect is identified:
1. STOP
Stop the affected process when required.
2. SEGREGATE
Immediately separate suspected material.
3. IDENTIFY
Clearly identify:
4. TRACE
Identify how much production has been completed since the last OK inspection.
5. CONTAIN
Inspect/contain all potentially affected material.
6. CORRECT
Work with Production/Contractor to correct the process.
7. VERIFY
Approve the process again before restarting.
8. RECORD
Record defect, quantity, root cause and action taken.
Production urgency is not a reason to pass a known defective harness.
11. REJECTION & REWORK REDUCTION
The engineer is responsible not only for finding defects but also for reducing their recurrence.
Maintain daily data for:
- Rejection
- Rework
- Defect type
- Part number
- Production line
- Operator/contractor
- Process responsible
Identify Top 3 recurring defects and conduct root-cause analysis using:
- 5 Why
- Pareto Analysis
- Fishbone Analysis
- Basic Root Cause Analysis
Work with Production and Quality Head on corrective actions.
Verify whether corrective action has actually eliminated the problem.
12. OPERATOR & CONTRACTOR QUALITY CONTROL
Where wiring harness production is performed through contractors, the Quality Engineer will:
- Apply the same quality standards to contractor production as company production.
- Conduct regular inspections irrespective of production pressure.
- Train operators on critical quality points.
- Explain recurring defects to contractor supervisors.
- Ensure defective material is not hidden, mixed or passed forward.
- Ensure rework is done according to approved procedure.
- Escalate repeated violations to Quality Head / Plant Head.
- Ensure operators understand the reason behind important quality requirements.
The engineer must be capable of being firm on quality while maintaining professional working relationships with production teams.
13. LINE QUALITY TRAINING
Provide regular practical training to operators regarding:
- Correct crimping
- Wrong crimp identification
- Terminal insertion
- Connector locking
- Wire colour identification
- Drawing/sample understanding
- Wrong cavity prevention
- Cross-wiring prevention
- Taping standards
- Defect identification
- Material segregation
- Handling of terminals/connectors
- 5S
- Customer quality requirements
Special training should be given whenever a new product is introduced or a repeated defect occurs.
14. POKA-YOKE & ERROR PREVENTION
Identify opportunities for simple error-proofing to prevent:
- Wrong wire
- Wrong terminal
- Wrong connector
- Wrong cavity
- Missing component
- Reverse polarity
- Wrong branch length
- Missing clip
- Wrong fuse
- Wrong switch/LED
- Incorrect assembly
Coordinate with Production/Engineering to introduce suitable jigs, fixtures, templates and poka-yoke systems.
15. MATERIAL IDENTIFICATION & TRACEABILITY
Ensure proper identification and traceability of:
- Wires
- Terminals
- Connectors
- Seals
- Sleeves
- WIP
- Finished harnesses
- Reworked material
- Rejected material
Prevent mixing of visually similar terminals, connectors and wires.
16. CHANGEOVER & LINE CLEARANCE
During product/part changeover:
- Ensure previous part material is removed.
- Check line clearance.
- Verify new drawing/BOM.
- Verify correct components.
- Verify correct crimping tools.
- Verify assembly board.
- Approve first piece again.
This is particularly important where multiple similar wiring harnesses are manufactured in the same area.
17. MEASURING & TESTING EQUIPMENT
The candidate should be capable of using/understanding:
- Vernier Caliper
- Micrometer
- Crimp Height Micrometer
- Pull-Force Tester
- Continuity Tester
- Wiring Harness Tester
- Multimeter
- Go/No-Go gauges, where applicable
- Checking fixtures
Ensure instruments are within calibration and used correctly.
18. QUALITY DOCUMENTATION
Maintain required records including:
- First-Piece Approval Report
- In-Process Inspection Report
- Crimp Inspection Report
- Pull-Test Report
- Patrol Inspection Report
- Rejection/Rework Report
- Line Clearance Report
- Non-Conformance Report
- Corrective Action Report
- Process Audit Report
- Traceability Records
- Training Records
- Daily Quality Report
Records must represent actual inspections performed and should not be filled only for audit compliance.
19. AUTOMOTIVE QUALITY SYSTEM REQUIREMENTS
Candidate should preferably have basic working knowledge of:
- ISO 9001
- IATF 16949
- Control Plan
- PFMEA
- Process Flow
- Work Instructions
- Traceability
- Poka-Yoke
- Corrective Action
- 5 Why
- 5S
- Kaizen
Support Quality Head during:
- Internal audits
- Customer audits
- Process audits
- Certification audits
20. DAILY QUALITY REPORTING
Daily report should include:
ParameterDaily StatusRunning LinesChecked / PendingFirst-Piece ApprovalsStatusIn-Process InspectionsCompleted / PendingPull TestsOK / Not OKTotal RejectionQty & %Total ReworkQty & %Top DefectsDefect-wiseLine StoppagesReasonCorrective ActionsOpen / ClosedRepeat ProblemsDetailsTraining GivenDetailsPending Quality IssuesAction & Responsibility
Critical quality issues must be reported immediately and should not wait for the daily report.
21. KEY PERFORMANCE INDICATORS (KPIs)KPIExpected PerformanceFirst-Piece Approval Compliance100%In-Process Inspection Compliance100%Crimp Inspection Compliance100%Pull-Test Compliance100%Wrong Wire/Terminal EscapeTarget ZeroWrong Cavity/Cross Wiring EscapeTarget ZeroCritical Defect EscapeZeroInternal RejectionContinuous ReductionReworkContinuous ReductionRepeat DefectsContinuous ReductionCorrective Action ClosureOn TimeQuality Documentation100%Customer Complaints due to Process EscapeTarget ZeroOperator Quality TrainingAs Planned22. QUALIFICATION & EXPERIENCE
Qualification:
Diploma / B.Tech / BE in:
- Electrical Engineering
- Electronics Engineering
- Automobile Engineering
- Mechanical Engineering
or equivalent technical qualification.
Preferred Experience: 2–5 years in Wiring Harness / Automotive Electrical / Electrical Assembly manufacturing.
Preference should be given to candidates having actual shop-floor experience in wiring harness production and quality.
23. ESSENTIAL TECHNICAL KNOWLEDGE
Candidate should have practical knowledge of:
- Wiring harness manufacturing process
- Wire cutting & stripping
- Crimping
- Terminals
- Connectors
- Crimp height measurement
- Pull-force testing
- Connector cavity inspection
- Harness assembly
- Continuity testing
- Engineering drawings
- BOM understanding
- Measuring instruments
- Rejection analysis
- Root-cause analysis
- Quality documentation
AutoCAD knowledge can be an added advantage but is not mandatory for this position.
24. REQUIRED PERSONAL SKILLS
The candidate should be:
- Strongly shop-floor oriented.
- Quality conscious.
- Alert and detail-oriented.
- Confident in taking decisions.
- Able to handle operators and contractors.
- Firm enough to stop defective production.
- Good at identifying recurring problems.
- Practical in problem-solving.
- Disciplined in documentation.
- Capable of training operators.
- Good at follow-up.
- Responsible and accountable.
- Willing to take ownership of quality problems.
- Focused on prevention rather than sorting/rework.
25. AUTHORITY
The Wiring Harness In-Process Quality Engineer is authorized to:
- STOP production for serious quality issues.
- HOLD suspected WIP/material.
- REJECT non-conforming material as per company procedure.
- Demand segregation and containment.
- Require 100% inspection when necessary.
- Stop use of incorrect terminals/connectors/wires.
- Stop a crimping operation when crimp/pull-force requirements are not achieved.
- Demand corrective action before restarting production.
- Escalate repeated violations to Quality Head / Plant Head.
26. CORE RESPONSIBILITY
The In-Process Quality Engineer should take ownership of quality throughout:
WIRE CUTTING → STRIPPING → CRIMPING → CONNECTOR INSERTION → HARNESS ASSEMBLY → TAPING/SLEEVING → ELECTRICAL TESTING → LINE OUTPUT
The person should not behave simply as an inspector who finds defects.
The expectation is:
CHECK → IDENTIFY → STOP → CONTAIN → FIND ROOT CAUSE → CORRECT → PREVENT RECURRENCE
MAIN OBJECTIVE
“Do not allow a defect to move to the next process. Detect the problem at its source, correct the process and prevent the same defect from occurring again.”
Pay: ₹18,000.00 - ₹25,000.00 per month
Work Location: In person
