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Key Responsibilities and Required Skills for Wire Technician

💰 $ - $

ManufacturingElectricalTelecommunicationsAerospaceField Service

🎯 Role Definition

The Wire Technician is responsible for accurate fabrication, assembly, installation and maintenance of electrical wiring, cable assemblies and wire harnesses across manufacturing and field environments. This role executes wire routing and termination per engineering drawings and industry standards (IPC-A-610, J-STD-001), performs functional and continuity testing, documents work for quality systems, and supports continuous improvement initiatives to improve reliability, reduce rework and maintain regulatory compliance. The ideal candidate combines strong manual dexterity, detailed blueprint/schematic reading, and disciplined adherence to workmanship and safety procedures.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Electrical Assembler
  • Cable/Connector Assembly Technician
  • Maintenance Technician / General Technician

Advancement To:

  • Senior Wire Technician / Lead Wire Harness Technician
  • Cable Shop Supervisor or Production Supervisor
  • Electromechanical Technician or Electrical Maintenance Technician
  • Harness Design Technician / Harness Engineer
  • Quality Inspector (IPC Certified)

Lateral Moves:

  • Test Technician (functional/ATE testing)
  • Field Service Technician / Installation Technician
  • Facilities or Plant Maintenance Electrician

Core Responsibilities

Primary Functions

  • Read, interpret and follow electrical schematics, wiring diagrams, assembly drawings and BOMs to assemble wire harnesses and cable assemblies to specification and tolerance standards.
  • Perform precise wire stripping, crimping and insulation displacement connector terminations using hand tools and pneumatic crimpers, ensuring crimp integrity and conductor retention per applicable IPC standards.
  • Solder components and pigtails to printed circuit boards (PCBs) and terminations following J-STD-001 soldering processes and using correct flux, solder alloy and temperature profiles.
  • Install heat-shrink tubing, over-molding and protective sleeving to specified lengths and positions to provide strain relief and environmental protection on cable assemblies.
  • Conduct continuity, resistance and insulation testing on assemblies using multimeters, hipot testers and cable analyzers to verify electrical continuity and absence of shorts.
  • Inspect and test produced wiring and harness assemblies against inspection criteria (IPC-A-610) and document acceptance or non-conformances in quality records.
  • Route, secure and dress wiring within enclosures and equipment using cable ties, clamps and channels to meet routing diagrams, EMI/EMC and serviceability requirements.
  • Fabricate wire harnesses to length and tolerance, cut and terminate cables to exact dimensions, and apply labels and part identification per shop standards and customer requirements.
  • Assemble and install connectors, backshells, seals and strain relief hardware to maintain environmental sealing and mechanical performance of cable assemblies.
  • Use crimp force verification tools and perform pull tests as required to validate connector terminations and ensure compliance with quality specifications.
  • Troubleshoot wiring faults in assemblies and installed systems using schematics, meggers, oscilloscopes and signal injectors; isolate and repair defects to restore functionality.
  • Maintain and update traveler documents, work orders, and production logs to support traceability and compliance with ISO/AS9100 or similar quality systems.
  • Set up and operate semi-automated harness machines, wire cutters/strippers, and automated crimping equipment; perform basic preventative maintenance and calibration checks.
  • Follow ESD control procedures when handling sensitive components and wiring for avionics, medical or electronics products.
  • Mount and terminate panel wiring, control cabinets and field junction boxes while coordinating with electrical and controls engineers to ensure correct phasing and control logic.
  • Collaborate with engineering and production teams to review production prints and suggest design-for-manufacture (DFM) adjustments to improve assembly efficiency and reduce rework.
  • Participate in first article inspections (FAI) and layout verification to validate compliance of initial production builds with customer specifications.
  • Apply corrosion-inhibiting treatments and sealing compounds as specified for outdoor or maritime cable assemblies and marine/telecom environments.
  • Maintain a clean, organized workspace and tool set, adhere to 5S practices, and ensure all tools are calibrated and tagged per shop policies.
  • Support production scheduling by reporting progress, material shortages and estimated completion times to supervisors and planners.
  • Perform field installation and termination of wiring on-site for retrofit projects, service calls and installations; communicate directly with customers to explain work performed and safety precautions.
  • Identify and document non-conforming product, perform root cause analysis, and execute corrective actions with quality and engineering teams to prevent recurrence.
  • Train and mentor junior technicians on wiring best practices, workmanship standards, and safety protocols including lockout/tagout (LOTO) and fall protection when doing installations.
  • Comply with all company safety policies, environmental rules and industry regulations when working in manufacturing floors or field sites, including PPE use and hazard communication.

Secondary Functions

  • Support continuous improvement and Lean manufacturing initiatives by proposing layout, tooling or process changes that reduce assembly time and defect rates.
  • Assist purchasing with reporting of recurring material issues (connector defects, cable inconsistencies) and suggest alternative approved suppliers.
  • Provide technical input during design reviews to improve cable routing, serviceability and connector selection early in the development cycle.
  • Help maintain inventory accuracy for wire, connectors and components through cycle counts and material reconciliation.
  • Participate in cross-functional project teams for new product introductions (NPI) to establish assembly work instructions and training materials.
  • Prepare and maintain calibration and maintenance records for hand tools, crimpers and test equipment used in the cable assembly process.
  • Support remote or on-site customer troubleshooting during escalations and warranty repairs, providing detailed service reports and repair documentation.
  • Create and update standard work documents, visual aids and training checklists to raise shop floor competency and product consistency.

Required Skills & Competencies

Hard Skills (Technical)

  • Wire harness assembly and cable assembly fabrication
  • Crimping to specification (manual and pneumatic crimpers) and crimp-force verification
  • Soldering to J-STD-001 standards and heat-shrink application
  • Reading and interpreting electrical schematics, wiring diagrams, BOMs and assembly drawings
  • IPC-A-610 workmanship acceptance criteria familiarity
  • Continuity, insulation resistance and hipot testing using multimeters, meggers and cable testers
  • Connector assembly and backshell termination, including sealed and environmentally-rated connectors
  • Use of hand tools, power tools, bench soldering stations and semi-automated harness machinery
  • Cable routing, cable management and strain relief installation for EMI/EMC and serviceability
  • Functional troubleshooting and fault isolation on wiring systems and installed equipment
  • Basic electrical knowledge (ohm’s law, circuits, grounding and bonding)
  • Use of measurement tools: calipers, micrometers, and pull-test gauges
  • Familiarity with NPI processes, first article inspection (FAI) and quality documentation (ISO/AS9100)
  • Experience with field installations, service calls and on-site termination work
  • Basic PLC/interfacing knowledge preferred (for control cabinet wiring)

(At least 10 technical skills included above; include certifications such as IPC-A-610, J-STD-001, OSHA as preferred credentials.)

Soft Skills

  • Strong attention to detail and focus on high workmanship quality
  • Manual dexterity and steady hand for fine wire work
  • Effective communication skills for cross-functional collaboration and customer interaction
  • Problem-solving mindset and methodical troubleshooting approach
  • Ability to prioritize tasks and manage time in a production or field schedule
  • Willingness to train and mentor junior technicians
  • Dependable, safety-conscious, and committed to following procedures and checklists
  • Adaptability to changing priorities in fast-paced manufacturing or field environments

Education & Experience

Educational Background

Minimum Education:

  • High school diploma or GED required; equivalent combination of education and work experience considered.

Preferred Education:

  • Associate degree or technical certificate in Electronics Technology, Electrical Technology, Mechatronics or related trade school diploma.
  • Certifications: IPC-A-610 Specialist, J-STD-001 Soldering Certification, OSHA 10/30, or manufacturer-specific connector training.

Relevant Fields of Study:

  • Electronics / Electrical Technology
  • Electromechanical Technology
  • Telecommunications / Network Cabling
  • Industrial Maintenance / Mechatronics

Experience Requirements

Typical Experience Range:

  • 1–5 years of hands-on cable/wire harness assembly, termination and testing experience.

Preferred:

  • 3–7 years experience in cable assembly for target industry (aerospace, defense, automotive, medical, telecom), with demonstrated IPC/J-STD compliance and experience performing FAIs, ECRs and corrective actions.
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