Process Engineer, Harness, Megapod

The Wire Harness Process Engineer develops, implements, validates, and continuously improves manufacturing processes for cable and wire harness assemblies. The role ensures all processes and workmanship fully comply with IPC/WHMA-A-620 (Requirements and Acceptance for Cable and Wire Harness Assemblies), the industry-consensus standard that defines materials, methods, tests, and visual/dimensional acceptance criteria (Target, Acceptable, and Defect conditions) for crimped, soldered, and mechanically secured interconnections as well as related assembly operations.

The engineer supports New Product Introduction (NPI), high-volume or high-reliability production (typically Class 2 or Class 3), quality, and cost/efficiency goals while maintaining process control, documentation, and operator competency to the latest revision of the standard (currently IPC/WHMA-A-620F).

- Develop, document, and maintain process flows, work instructions, visual aids, SOPs, routers, and control plans that meet IPC/WHMA-A-620 requirements for wire preparation (cutting, stripping, tinning), crimping (height, bellmouth, insulation support, conductor brush, pull-force), soldering, splicing, IDC, ultrasonic welding, connector/terminal insertion, routing/bundling/lacing, shielding/grounding, sleeving/heat-shrink, labeling, overmolding/potting, and testing
- Establish and qualify processes to achieve the specified product class (Class 1 – General Electronic Products; Class 2 – Dedicated Service; Class 3 – High-Reliability) with appropriate inspection frequency and process indicators
- Specify, design, procure, and validate tooling, fixtures, jigs, crimp applicators, automated wire processors, and testers; perform crimp validation (pull testing, crimp height, microsectioning) and first-article inspections
- Support prototype builds, first-time builds, and production ramp-up; conduct Design for Manufacturability and Assembly (DFMA) reviews of drawings, schematics, wire lists, and BOMs
- Lead root-cause analysis, PFMEA updates, and CAPA for defects (e.g., nicked/broken strands, incomplete crimps, improper seating, routing violations, test failures)
- Train and certify operators and inspectors on IPC/WHMA-A-620 workmanship criteria, visual inspection, and process controls; maintain training records
- Analyze yield, cycle time, quality data, and SPC; drive Lean, 5S, and continuous-improvement projects to reduce cost, improve throughput, and eliminate defects
- Collaborate with Design Engineering, Quality, Supply Chain, and Production; review ECOs and implement process changes
- Ensure additional customer or industry requirements (AS9100, ISO 9001, automotive, aerospace, medical, etc.) are integrated with IPC/WHMA-A-620
- Stay current with standard revisions, IPC-D-620 (design companion), and related documents; participate in internal audits and customer/supplier assessments

- Degree in Engineering, or equivalent experience
- 5+ years of manufacturing process engineering experience, ideally with wire harness, cable assembly, or interconnect processes
- Working knowledge of IPC/WHMA-A-620; IPC/WHMA-A-620 Certified Application Specialist (CIS) or Certified Trainer (CIT) strongly preferred
- Proven experience developing and maintaining process documentation, including work instructions, visual aids, SOPs, control plans, and PFMEAs
- Hands-on experience with tooling, fixtures, jigs, crimp applicators, automated wire processors, pull testing, crimp height measurement, and microsectioning
- Experience supporting NPI, prototype/first-article builds, production ramp-up, and Design for Manufacturability and Assembly (DFMA) reviews
- Strong skills in root-cause analysis, CAPA, SPC, yield/cycle-time analysis, and driving Lean/5S continuous-improvement projects with measurable results
- Demonstrated ability to train and certify operators and inspectors on workmanship standards and process controls
- Proficiency with Microsoft Office, ERP/MRP systems, data analysis tools (Minitab or equivalent preferred), and basic CAD for fixtures
- Familiarity with additional quality standards (AS9100, IATF 16949, ISO 9001, IPC-A-610, etc.) and experience in automotive, aerospace, medical, or high-reliability environments

Benefits

Along with competitive pay, as a full-time Tesla employee, you are eligible for the following benefits at day 1 of hire:

- Medical plans > plan options with $0 payroll deduction
- Family-building, fertility, adoption and surrogacy benefits
- Dental (including orthodontic coverage) and vision plans, both have options with a $0 paycheck contribution
- Company Paid (Health Savings Accounts) HSA Contribution when enrolled in the High-Deductible medical plan with HSA
- Healthcare and Dependent Care Flexible Spending Accounts (FSA)
- 401(k) with employer match, Employee Stock Purchase Plans, and other financial benefits
- Company paid Basic Life, AD&D
- Short-term and long-term disability insurance (90 day waiting period)
- Employee Assistance Program
- Sick and Vacation time (Flex time for salary positions, Accrued hours for Hourly positions), and Paid Holidays
- Back-up childcare and parenting support resources
- Voluntary benefits to include: critical illness, hospital indemnity, accident insurance, theft & legal services, and pet insurance
- Weight Loss and Tobacco Cessation Programs
- Tesla Babies program
- Commuter benefits
- Employee discounts and perks program