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About the Role

Lead a new wire harness assembly operation from the ground up, supporting complex military and aerospace programs. This role involves establishing manufacturing processes, defining tooling, and providing technical leadership while remaining hands-on in production.

Responsibilities

• Review technical drawing packages.
• Define manufacturing processes.
• Identify and select required tooling and equipment.
• Establish production work areas.
• Support material and tooling procurement.
• Develop processes for high-quality aerospace wire harness assemblies.
• Serve as the technical and program lead for wire harness manufacturing activities.
• Build and troubleshoot harness assemblies.
• Train future technicians.
• Interface with Quality and Engineering personnel.
• Support customer requirements.
• Provide technical leadership throughout the manufacturing process.
• Establish manufacturing processes, work instructions, travelers, tooling requirements, and inspection/test processes for new harness assemblies.
• Support material procurement, tooling selection, manufacturing planning, and production readiness activities.
• Troubleshoot manufacturing issues and provide hands-on technical directions to other technicians.

Requirements

• Demonstrated ability to interpret complex engineering drawings, wiring diagrams, wire lists, bills of material (BOMs), specifications, and manufacturing requirements.
• Strong working knowledge of IPC/WHMA-A-620 workmanship and inspection requirements.
• Experience working to SAE AS50881 or comparable aerospace wiring requirements.
• Extensive hands-on experience with aerospace wire harness manufacturing processes including wire cutting, stripping, preparation, and routing; precision crimping and contact termination; connector assembly and contact insertion/extraction; shielding, overbraid, and EMI/RFI back shell termination; solder sleeves and heat-shrink components; coaxial cable termination; twinax and/or quadrax termination; harness identification and labeling; harness layout and build-board/template development.
• Demonstrated knowledge of crimp tooling, dies, turrets, positioners, insertion/extraction tools, and associated inspection/calibration requirements.
• Experience performing and/or overseeing electrical continuity, open/short, and miswire testing of completed harness assemblies.
• Experience with automated wire harness test equipment such as Cirris or equivalent is highly desirable.
• Experience with crimp pull testing and process validation.
• Demonstrated experience working with Microsoft Office applications.
• Ability to work in an on-site manufacturing environment.
• US Citizenship
• Minimum 10+ years of direct hands-on experience manufacturing complex aerospace, defense, or other high-reliability cable and wire harness assemblies.
• IPC/WHMA-A-620 certification.
• IPC J-STD-001 certification.
• Ability to determine appropriate manufacturing tooling and equipment based upon engineering drawings, component requirements, and manufacturer specifications.

Skills

• Aerospace wire harness manufacturing
• Technical drawing interpretation
• Manufacturing process definition
• Tooling and equipment selection
• Production area establishment
• Material and tooling procurement support
• Wire harness assembly
• Troubleshooting
• Training
• Quality and Engineering interface
• Customer support
• Technical leadership
• Work instruction development
• Inspection and testing processes
• Crimp tooling knowledge
• Automated wire harness test equipment
• Crimp pull testing
• Process validation
• Communication skills
• Independent work
• Team collaboration
• Microsoft Office applications

Location

• Bohemia, NY

Work Type

• On-Site
• Full-time

Experience Level

• Lead
• 10+ years

Education Level

• High School diploma

Benefits

• Tuition reimbursement
• Profit sharing
• 401K with company match
• Private medical, vision and dental insurance

About the Company

• Dayton T. Brown, Inc. is a recognized leader in engineering, testing, logistics, and mission-critical military systems.
• A stable, successful organization.
• Innovative work environment.
• Advancement potential.
• Work/Life balance and family values.

Equal Opportunity

• Dayton T. Brown, Inc. is an equal opportunity employer - Veterans and Disabled