Machine Operator - Wire Harness

SUMMARY The Wire Harness Machine Operator is responsible for operating, setting up, monitoring, and maintaining automated wire processing equipment used in the manufacturing of HVAC climate control, electrical, and electronic control products. This position performs wire cutting, stripping, crimping, labeling, and harness assembly operations while ensuring quality, safety, and production requirements are consistently met. The ideal candidate possesses strong mechanical aptitude, attention to detail, and a commitment to continuous improvement in a fast-paced manufacturing environment.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Include the following. Other duties may be assigned. Responsibilities and activities may change at any time with or without notice.

• Operate Komax Zeta, Schleuniger Multistrip, and related wire processing equipment and software.
• Set up machines for production runs, including changeover of wire reels, dies, ferrules, terminals, labels, and ink supplies.
• Read and interpret blueprints, schematics, work orders, bills of material, wire lists, and assembly instructions.
• Cut, strip, crimp, label, and process wires and cables according to engineering specifications and customer requirements.
• Assemble wire harnesses, connectors, terminals, protective sleeving, heat shrink, and related electrical components.
• Perform first-piece, in-process, and final inspections to verify product quality.
• Utilize pull-test equipment, crimp micrometers, calipers, and other inspection tools to validate product conformance.
• Identify and segregate defective materials and notify supervision of quality issues.
• Troubleshoot machine issues, clear minor jams, and make basic machine adjustments to maintain production flow.
• Perform daily equipment inspections and preventive maintenance activities.
• Maintain accurate production records, quality documentation, and manufacturing data.
• Stage and manage inventory of wire, terminals, connectors, labels, and production materials.
• Monitor material availability and communicate shortages or discrepancies to supervisors.
• Maintain traceability and proper handling of materials throughout the manufacturing process.
• Follow all company safety policies, work instructions, and manufacturing procedures.
• Maintain a clean and organized work areain accordance with5S andLean manufacturing principles.
• Support continuous improvement initiatives focused on safety, quality, delivery, and productivity.
• Work collaboratively with Manufacturing, Engineering, Quality, Planning, and Maintenance teams to resolve production issues.
• Meet established productivity, quality, and attendance standards.
• Participate in training programs and maintain required skill certifications.
• Perform any other similar or associated duties necessary to accomplish job objectives or as assigned by the immediate supervisor.

QUALIFICATIONS

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Education

• High School Diploma or GED required.
• Technical training in manufacturing, electronics, electrical assembly, or automation preferred.

Experience

• Minimum one (1) year of manufacturing, machine operation, wire processing, or assembly experience preferred.
• Experience operating Komax, Schleuniger, or similar wire processing equipment is preferred.
• Experience in wire harness, cable assembly, electronics manufacturing, or HVAC controls manufacturing is a plus.

Language and Communication Skills

• Ability to read, understand, and follow written work instructions, blueprints, and procedures.
• Ability to communicate effectively with supervisors, engineers, quality personnel, and team members.
• Must be able to read, write, and speak English.

Technical Knowledge

• Knowledge of wire harness assembly, electrical components, terminals, connectors, and crimping processes preferred.
• Ability to use precision measuring and testing devices.
• Basic computer skills and experience working with machine software interfaces.
• Familiarity with ERP and manufacturing systems is desirable.

Mechanical Aptitude

• Strong mechanical aptitude and troubleshooting abilities.
• Ability to perform machine setups, adjustments, and basic maintenance activities.

Quality Focus

• Strong attention to detail and commitment to producing high-quality products.
• Understanding of ISO 9001 quality standards is preferred.

Lean Manufacturing

• Understanding of Lean Manufacturing concepts, 5S, waste reduction, and continuous improvement initiatives preferred.

Teamwork / Collaboration

• Demonstrated ability to work effectively within a production team environment.
• Positive attitude and willingness to support departmental goals and objectives.

Organizational Support

• Follows policies and procedures.
• Completes tasks accurately and on time.
• Supports organizational goals and values.

Decision Making & Problem Solving

• Ability to identify issues, analyze information, and implement corrective actions within scope of responsibility.
• Ability to prioritize workload and respond effectively in a fast-paced manufacturing environment.

Attention to Detail

• Ability to perform repetitive work requiring accuracy and precision.
• Ability to distinguish wire colors, labels, and component markings accurately.

OTHER SKILLS

• Knowledge of wire processing equipment, crimping equipment, and harness assembly processes.
• Basic knowledge of electrical drawings, schematics, and manufacturing documentation.
• Familiarity with ISO 9001 quality requirements.
• Basic understanding of lean manufacturing principles and continuous improvement methodologies.
• Ability to use hand tools, inspection tools, and measuring devices.
• Strong problem-solving, troubleshooting, and organizational skills.
• Ability to work independently with minimal supervision.
• Good adaptability and willingness to learn new processes and technologies.

CERTIFICATES, LICENSES, REGISTRATIONS

• IPC/WHMA-A-620 certification preferred.
• Manufacturing, quality, or technical certifications preferred.
• Lean Manufacturing training a plus.
• Forklift certification a plus.

SUPERVISORY RESPONSIBILITIES

None.

PHYSICAL DEMANDS

• While performing the duties of this job, the employee is regularly required to stand, walk, use hands and fingers, handle objects, tools, or controls, and communicate effectively.
• The employee is frequently required to reach, bend, twist, squat, and lift materials.
• The employee must regularly perform repetitive hand and wrist movements.
• The employee must regularly lift and/or move up to 50 pounds.
• Specific vision abilities required include close vision, color vision, depth perception, and the ability to adjust focus.
• Ability to work standing for extended periods throughout the shift.

WORK ENVIRONMENT

• Manufacturing and warehouse environment.
• Regular exposure to automated machinery and moving mechanical equipment.
• Use of personal protective equipment (PPE) as required.
• Frequent exposure to production equipment, material handling devices, and manufacturing processes.
• Noise levels are typically moderate and may vary depending on production activity.
• Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions of the position.

Carel is an Equal Opportunity Employer.

Monday - Friday 6:30 am – 3:00 pm