Lead, Wire Harness Technician (Manufacturing)
Summary:
VIAVI (NASDAQ: VIAV) is a global provider of network test, monitoring and assurance solutions for telecommunications, cloud, enterprises, first responders, military, aerospace, and railway. VIAVI is also a leader in light management technologies for 3D sensing, anti-counterfeiting, consumer electronics, industrial, automotive, government and aerospace applications.We are the people behind the products that help keep the world connected at home, school, work, at play, and everywhere in between. VIAVI employees are passionate about supporting customer success and we welcome people who bring their best every day to the company – to question, to collaborate and to push for solutions that will delight our customers.
The Wire Harness Lead is responsible for overseeing and participating in the assembly and inspection of wire harnesses and cables, ensuring all work complies with quality, safety, and industry standards, including IPC/WHMA-A-620. This role includes hands-on assembly, in-process inspection, team leadership, training, and collaboration with engineering and production teams. The Lead plays a key role in driving 5S, Lean manufacturing, and continuous improvement initiatives while ensuring production goals are met with precision and efficiency.
Duties & Responsibilities:
Key Responsibilities:
Leadership and Coordination
- Lead a team of 4 wire harness assemblers, ensuring daily tasks are completed efficiently and accurately.
- Conduct training for team members on assembly techniques, safety practices, and quality standards.
- Collaborate with the Industrial Engineer to optimize workflow, improve processes, and implement ergonomic and efficiency improvements.
- Champion and lead 5S workplace organization and continuous improvement initiatives on the production floor.
- Promote a culture of accountability, teamwork, and high performance.
Wire Preparation and Harness Assembly
- Perform and oversee wire preparation, stripping, and assembly according to schematics and instructions.
- Ensure proper routing, securing, and labeling of harnesses to meet design specifications.
- Guide team members in crimping, soldering, and other connection techniques.
In-Process Inspection and Testing
- Perform and oversee in-process inspection and testing of cables and wire harnesses to ensure compliance with IPC/WHMA-A-620 standards.
- Identify and correct defects or non-conformities during the assembly process.
- Maintain accurate documentation of inspection results and corrective actions.
Final Testing and Quality Control
- Supervise and perform functional testing of completed wire harnesses.
- Ensure all assemblies meet performance and quality requirements before release.
- Document test results, quality issues, and resolutions in accordance with company procedures.
Safety and Housekeeping
- Promote and enforce safety protocols, including ESD standards and proper tool usage.
- Ensure the work area is clean, organized, and compliant with safety regulations.
- Lead by example in maintaining a safe and efficient work environment.
Collaboration and Reporting
- Communicate production updates, issues, and improvement opportunities to management.
- Assist in documentation related to production, quality assurance, and training.
- Support cross-functional initiatives and participate in Lean and Kaizen activities.
Inventory Oversight (Secondary Responsibility)
- Monitor inventory levels of assembly components and coordinate with inventory staff to ensure availability.
- Ensure proper storage and handling of materials in compliance with safety standards.
Pre-Requisites / Skills / Experience Requirements:
Preferred Skills & Qualifications:
Education
- High school diploma or GED required.
Experience
- Minimum 5 years of experience in wire harness assembly or a related field.
- Prior leadership or team lead experience preferred.
Technical Skills
- Proficient in reading and interpreting wiring diagrams and schematics.
- Skilled in wire preparation, crimping, soldering, and testing techniques.
- Experience with in-process inspection and functional testing of harnesses.
- Knowledge of and compliance with IPC/WHMA-A-620 standards is required.
- Familiarity with Lean manufacturing principles and continuous improvement methodologies.
Soft Skills
- Strong leadership, communication, and interpersonal skills.
- High attention to detail and commitment to quality.
- Ability to motivate and guide a team in a fast-paced environment.
- Problem-solving mindset with a proactive approach to challenges.
Certifications (Preferred)
- IPC/WHMA-A-620 certification.
- Other relevant certifications in wire harness assembly, crimping, or safety practices.
Working Conditions
- Clean, organized production environment with a focus on safety and efficiency.
- Flexible working hours, including potential overtime and weekend shifts.
- Use of hand tools, power tools, and testing equipment.
Physical Demands
- Ability to stand, sit, and perform tasks requiring manual dexterity for extended periods.
- Ability to lift up to twenty-five pounds as needed.
If you have what it takes to push boundaries and seize opportunities, apply to join our team today.
VIAVI Solutions is an equal opportunity and affirmative action employer – minorities/females/veterans/persons with disabilities.
