Process Engineer, Harness, Megapod Tesla Motors, Inc. paid holidays, flex time, 401(k) United States, Texas, Brookshire Oct 09, 2026

What to Expect 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 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

). What You'll Do

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 What You'll Bring

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 Notify me of jobs like this