SR MFG & PROCESS DVL ENGINEER - Cable Assembly

At TE, you will unleash your potential working with people from diverse backgrounds and industries to create a safer, sustainable and more connected world.

Job Overview The Senior Manufacturing and Process Development Engineer will lead the development, industrialization, qualification, and launch of manufacturing processes for new and existing products.

The role focuses on cable and harness assembly for Industrial and Commercial Transportation BU.

In this role you will collaborate with Product Engineering, Quality, Project Management, Procurement, equipment suppliers, and manufacturing plants to deliver safe, capable, scalable, and cost-effective production processes.

Job Requirements Process Development and Industrialization

• Translate product, customer, and quality requirements into manufacturing process concepts and equipment requirements.
• Lead early design-for-assembly and design-for-manufacturing activities to improve manufacturability, scalability, process robustness, and total manufacturing cost.
• Develop process flows and support alignment among PFMEA, Control Plan, machine specifications, and qualification requirements.
• Estimate capital requirements and manufacturing cost drivers - including cycle time, labor, scrap, material utilization, floor space, and equipment utilization. Create scenarios that scale manufacturing process with demand, and optimize CAPEX spend.
• Support engineering, design-validation, process-validation, and production sample builds.
• Plan and execute equipment qualification and process-validation activities.

Automation and Equipment Development

• Develop lean, flexible, modular, and scalable manufacturing solutions for cable assemblies, harnesses, and associated test processes for cables and harnesses including Data Connectivity, E-Mobility and Low Voltage Harnesses.
• Prepare equipment specifications, technical requirements, requests for quotation, and qualification plans.
• Conduct technical quote reviews and provide supplier recommendations in collaboration with Procurement and project stakeholders.
• Lead equipment concept and design reviews with internal automation teams, integrators, application-tooling teams, and external suppliers.
• Apply run-at-rate studies, capability analysis, measurement system analysis, correlation studies, and design of experiments to verify process and equipment performance.
• Use 3D CAD to develop or review fixtures, jigs, gauges, tooling, and production-intent process concepts.

Launch and Plant Support

• Coordinate equipment installation, setup, acceptance, qualification, and transfer to the receiving manufacturing location.
• Train plant engineering, maintenance, technician, and production personnel on newly introduced equipment and processes.
• Support equipment debug, process optimization, failure analysis, and production ramp-up.
• Lead structured issue resolution using data-driven problem-solving methods.
• Conduct mass-production trials, capacity analysis, value-stream reviews, and run-at-rate studies to confirm production readiness.
• Establish clear action plans, owners, due dates, and escalation paths for open technical issues.

Project and Supplier Management

• Manage multiple process-development and capital-equipment projects while balancing quality, cost, timing, and technical risk.
• Manage local and global equipment suppliers from concept through installation and production release.
• Track project milestones, technical risks, capital spending, supplier deliverables, and recovery plans.
• Communicate project status and technical risks clearly to cross-functional teams and leadership.
• Mentor team members and share manufacturing process development best practices.

What Your Background Should Look Like

• Bachelor’s degree in mechanical, Industrial, Mechatronics, Manufacturing, Electrical, or a related engineering discipline.
• Five or more years of experience in process development or manufacturing of Cable and harness assembly.
• Knowledge of various cable processing technologies including feeding, cutting, stripping, joining technologies (crimping, welding, soldering etc.), harness assembly, testing.
• Working knowledge of process flow, PFMEA, Control Plan, MSAs, capability analysis, DOEs, run-at-rate, and structured problem-solving methods.
• Experience with lean manufacturing and continuous-improvement principles.
• Strong project-management, organization, negotiation, and technical-communication skills.
• Professional proficiency in English and Spanish, including technical discussions and documentation.
• Ability to travel domestically and internationally up to 30%, including occasional extended trips for equipment acceptance, installation, and launch support.

Competencies SET : Strategy, Execution, Talent (for managers)