Position Title: Engineer / Sr. Engineer / Assistant Manager
Department: Production
Industry: Automotive Component Manufacturing & EV – Wire Harness / Sheet Metal / Welded & Molded Parts
Experience Required: 8–10 years of experience in automotive parts manufacturing, with proven expertise in Wire Harness and Electrical Component production.
Educational Qualification: Diploma / B.E. / B.Tech in Mechanical, Electrical, or Electronics Engineering.
Reporting To: DGM – Production
Location: Udaipur, Rajasthan
OBJECTIVE OF THE ROLE
To lead and manage the production function for wire and cable harness manufacturing operations, ensuring products meet ISO and customer quality standards, driving continuous improvement, line balancing, lean manufacturing, Low cost automation, fixture concept, Poke-yoke, Kaizen, localization initiatives, and effective troubleshooting of process and product quality issues across all manufacturing stages.
KEY RESPONSIBILITIES
Leadership & Production System
➤ Lead and manage the production function and teams across wire harness manufacturing lines.
➤ Develop, implement, and maintain the production system in compliance with ISO.
➤ Drive internal audits, management reviews, and CAPA (Corrective & Preventive Action) closures for quality non-conformities.
➤ Collaborate with Plant Head or seniors and cross-functional teams to align production target with plant and business goals.
➤ Champion Lean, Six Sigma, Kaizen, 5S, and Total Quality Management (TQM) initiatives.
Wire Harness Production
➤ Ensure production of wire harness sub-assemblies, assemblies, connectors, and terminals as per customer and engineering specifications.
➤ Drive Line Balancing on wire harness assembly lines to optimize manpower and machine utilization, cycle time, and throughput while maintaining quality standards.
➤ Lead troubleshooting of process, machine, and product quality issues on the shop floor, including crimping, splicing, molding, and continuity/functional testing.
➤ Drive localization of wire harness components, connectors, and raw materials, ensuring supplier qualification, PPAP approval, and quality validation of localized parts.
➤ Conduct root cause analysis (5-Why, Fishbone, 8D) for in-house rejections, customer complaints, and field returns, and implement effective countermeasures.
➤ Ensure SPC application critical/special characteristics as required by the customer.
Supplier & Customer Quality
➤ Manage supplier quality assessments, QMS audits, and supplier rating for wire harness components and raw materials.
➤ Production ramp-up through scientifically method.
➤ Address customer complaints and quality escalations, ensuring root cause identification, corrective action, and PPM reduction.
➤ Maintain strong customer relationships to ensure sustained quality satisfaction and reduced return PPM.
Documentation, Reporting & Team Development
➤ Ensure accurate and updated quality documentation as per ISO requirements (control plans, PFMEA, work instructions, inspection standards).
➤ Prepare and present production performance reports, KPIs, and improvement trends to senior management.
➤ Train, mentor, and develop the production team including engineers and line inspectors on quality procedures, troubleshooting techniques, and best practices.
KEY SKILLS & COMPETENCIES
➤ Strong technical knowledge of Wire Harness manufacturing processes (crimping, splicing, molding, testing).
➤ Hands-on experience in Line Balancing and manpower/process optimization on assembly lines.
➤ Proven skills in Troubleshooting of process, product, and machine-related quality issues.
➤ Experience driving Localization of components and supplier development for import substitution.
➤ Sound knowledge of ISO, FMEA, SPC, MSA, 7 QC Tools, 8D Problem Solving.
➤ Strong leadership, team management, and cross-functional collaboration skills.
➤ Proficiency in MS Office, SAP, ERP systems, and quality reporting tools.
QUALIFICATION & EXPERIENCE
➤ Diploma / Degree in Mechanical, Electrical, or Electronics Engineering.
➤ 8-10 years of relevant experience in automotive component manufacturing, with significant exposure to wire harness or electrical/electronic parts quality.
➤ Prior experience in automotive sector Tier-1 organization is mandatory.
