Engineer - NPI & Engineering (PCBA & Cable/Wire Harness Manufacturing)

Job Title: NPI Engineer – PCBA & Cable/Wire Harness Manufacturing

Location: Hyderabad

Experience : 4–8 Years

Industry: Electronics Manufacturing Services (EMS)

Job Summary

We are seeking an experienced NPI (New Product Introduction) Engineer with strong expertise in PCBA and Cable/Wire Harness manufacturing. The candidate will be responsible for managing the complete product introduction lifecycle from RFQ through mass production, establishing robust manufacturing processes, developing tooling and fixtures, and ensuring successful product launches with high quality, productivity, and reliability.

The ideal candidate should possess hands-on experience in SMT, through-hole assembly, wire harness manufacturing, tooling development, and process engineering within a high-mix, low-volume or high-reliability manufacturing environment.

Key Responsibilities

1. New Product Introduction (NPI)

• Lead complete NPI lifecycle from RFQ, prototype, pilot builds, and production ramp-up to mass production.
• Review customer design inputs including BOMs, Gerber files, assembly drawings, cable schematics, and engineering specifications.
• Conduct DFM (Design for Manufacturability), DFA (Design for Assembly), and DFT (Design for Testability) reviews for PCB assemblies and wire harness products.
• Coordinate with customers, engineering, production, quality, procurement, and suppliers to ensure successful project execution.
• Support prototype builds and process validation activities.

2. Tooling & Fixture Development

• Design, develop, validate, and implement manufacturing tooling and fixtures including:
• SMT stencils
• Wave solder pallets
• Reflow carriers
• Assembly fixtures and poka-yoke systems
• Wire harness nail boards and routing fixtures
• Crimping applicators
• Wire cutting, stripping, and termination tools
• Collaborate with external tooling vendors for design reviews, fabrication, qualification, and maintenance.
• Ensure tooling meets productivity, safety, ergonomic, and quality requirements.

3. Cable & Wire Harness Engineering

• Interpret cable harness drawings, wiring diagrams, schematics, and customer specifications.
• Define and optimize manufacturing processes for:
• Wire cutting and stripping
• Crimping and soldering
• Connector assembly
• Cable routing and dressing
• Heat shrink application and labeling
• Select appropriate wires, terminals, connectors, sleeves, heat shrink materials, and accessories.
• Implement error-proofing (Poka-Yoke) techniques to eliminate assembly defects.
• Establish workmanship standards in compliance with industry requirements.

4. Process Engineering (PCBA & Harness)

• Develop and optimize SMT manufacturing processes including solder paste printing, component placement, and reflow soldering.
• Define assembly processes for cable harnesses and box-build integration.
• Support SPI, AOI, and AXI programming and process optimization.
• Troubleshoot manufacturing issues related to soldering, crimping, assembly, and testing.
• Drive continuous improvement initiatives to improve productivity and quality.

5. Documentation & Compliance

• Develop and maintain:
• Process Flow Diagrams
• PFMEA
• Control Plans
• Work Instructions (WI)
• Standard Operating Procedures (SOPs)
• Process Validation Reports
• Ensure compliance with applicable industry standards and customer requirements including:
• IPC-A-610
• IPC/WHMA-A-620
• AS9100
• NADCAP requirements where applicable
• Support document control and engineering change implementation.

6. Cross-Functional Collaboration

• Work closely with Production, Quality, Supply Chain, Manufacturing Engineering, and Customer teams.
• Support First Article Inspection (FAI), PPAP submissions, customer audits, and process audits.
• Manage Engineering Change Notices (ECN/ECO) and technical clarifications.
• Participate in customer meetings and project reviews.

7. Yield Improvement & Problem Solving

• Monitor and improve First Pass Yield (FPY) for PCBA and wire harness production lines.
• Conduct root cause analysis using:
• 5 Why
• 8D Methodology
• Fishbone Analysis
• Pareto Analysis
• Implement corrective and preventive actions (CAPA).
• Improve process capability, reduce defects, and drive cost reduction initiatives.

Required Qualifications

• Bachelor's Degree in Electronics Engineering, Electrical Engineering, Manufacturing Engineering, or related field.
• 5+ years of experience in NPI, Manufacturing Engineering, or Process Engineering within EMS or wire harness manufacturing environments.
• Strong knowledge of PCBA manufacturing processes including SMT and through-hole assembly.
• Hands-on experience in cable and wire harness manufacturing processes.
• Knowledge of crimping standards, pull-force requirements, and workmanship criteria.
• Experience in tooling and fixture development including nail boards, assembly fixtures, and soldering pallets.
• Familiarity with Gerber analysis tools such as CAM350, Valor, or equivalent.
• Strong troubleshooting and problem-solving skills.

Preferred Qualifications

• Experience in Aerospace, Defense, Medical, or other high-reliability manufacturing industries.
• Knowledge of traceability systems, serialization, and lot control requirements.
• Exposure to box-build and system integration assemblies.
• Understanding of Lean Manufacturing, Six Sigma, and Continuous Improvement methodologies.
• IPC-A-610 and IPC/WHMA-A-620 certification preferred.
• Experience working in AS9100 and NADCAP-compliant environments.

Key Competencies

• New Product Introduction (NPI)
• PCBA Manufacturing
• Cable & Wire Harness Engineering
• Tooling & Fixture Development
• Process Validation
• Root Cause Analysis
• Cross-Functional Collaboration
• Continuous Improvement
• Quality & Compliance Management
• Customer Communication