Senior Process Engineer, Cable & Harness

The posting, as Firestorm wrote it

Cable and harness is where aircraft programs quietly lose schedule. The design is released, the wire list looks fine, and then the first build takes three times as long as anyone planned, the second one comes out different, and nobody can say exactly why. This role exists so that doesn't happen here.

As a Senior Process Engineer for cable and harness, you own the process from the first prototype bundle to a supplier building at rate. You'll develop and prove the process in-house during NPI — wire prep, crimp, termination, shield termination, backshells, overmold — then package it and stand it up at a harness supplier without losing the detail in the handoff. RF assemblies are supplier-built; you own the process and the technical oversight, and you review test criteria with engineering rather than building those yourself.

This is a bench job as much as a planning job. You'll be at the formboard during first builds finding out where your process was wrong, and you'll be at a supplier's facility making sure the way they run it matches the way you wrote it. You'll also own the test side: continuity, hipot, and insulation resistance for non-RF assemblies, including the fixtures and adapter cables that make it work.

The processes and tooling you build here travel. What you develop gets transferred, so write it for someone who wasn't in the room.

We're hiring at the mid or senior level depending on experience. Senior candidates will own supplier transfers end to end from day one. Mid-level candidates will own in-house process and test, and grow into transfer ownership.

What You'll Do

• Develop cable and harness manufacturing processes for prototype and early production: wire prep, crimp, termination, shield and braid termination, backshell and strain relief, overmold and potting, breakout and routing
• Author manufacturing planning and documentation — work instructions, formboard layouts, wire lists, MBOMs, routings, and travelers — and keep them current as the configuration moves
• Establish and hold process controls: crimp height and pull-test sampling plans, tool verification and calibration intervals, cure and cycle parameters, and ESD controls
• Design, source, build, and prove out tooling and fixtures: formboards, crimp tooling and positioners, hold-downs, pull-test setups, and overmold tooling
• Own non-RF harness electrical test, including test programs, adapter cables, fixtures, and failure disposition with engineering
• Review RF cable assembly test criteria with engineering, flow them to suppliers, and assess incoming test data and CoCs against what was specified
• Build the manufacturing data package for source transfer and own the transition plan: timeline, tooling duplication or shipment, operator training, dual-source strategy, and the criteria that close out in-house build
• Lead supplier process qualification, first article, on-site audits, and build readiness reviews, and serve as the technical point of contact for su

[…]
ance

• Critical Illness insurance
• Accident insurance
• Basic Life/AD&D, short-term and long-term disability insurance, 100% covered by Firestorm. Plus, the option to purchase additional life insurance for you and your family.
• Mental Health Resources: We provide free mental health resources 24/7 including therapy and more. Additional work-life services, such as free legal and financial support, are available to you as well.

Export Control Compliance

To conform to U.S. government export control regulations, including the International Traffic in Arms Regulations (ITAR) and Export Administration Regulations (EAR), you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or otherwise eligible to obtain the required authorizations from the U.S. Department of State or U.S. Department of Commerce.

Equal Opportunity Statement

Firestorm is an equal opportunity employer, committed to creating a diverse and inclusive workplace, and upholding equitable hiring practices. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other characteristic under federal, state, or local law, including those with a criminal history, in a manner consistent with the requirements of applicable state and local laws, including the CA Fair Chance Initiative for Hiring Ordinance. We actively encourage members of recognized minorities, women, Veterans, and those with disabilities to apply, and we work to create a welcoming and supportive environment for all applicants throughout the interview process.

Firestorm is committed to fostering an inclusive and accessible work environment. If you require accommodations or assistance during the application process, please don’t hesitate to reach out to us at careers@launchfirestorm.com so we can provide the support you need.