Yazaki India Hiring Production Engineer – Wiring Harness Division 

If you are an experienced production professional looking to grow your career in the automotive sector, here is an excellent opportunity for you. Yazaki, a globally recognized leader in automotive wiring harness systems, is inviting applications for the position of Production Engineer – Wiring Harness Division. This role is based at Yazaki’s facility in Mandal Becharaji Road, Jalisana, Gujarat.

This detailed job article will guide you through the responsibilities, required skills, experience expectations, and application process.

About Yazaki – A Global Automotive Leader

Yazaki is one of the world’s top suppliers of automotive electrical solutions. The company develops cutting-edge wiring harnesses, power distribution components, electronic systems, and vehicle interfaces used by leading automotive manufacturers.

With a strong presence in India, Yazaki is known for:

• High-quality manufacturing
• Strong engineering capabilities
• Continuous improvement culture (Kaizen)
• Global automotive partnerships

Joining Yazaki means being part of a company that emphasizes technology, efficiency, and excellence in production.

Job Profile: Production Engineer – Wiring Harness Division

Qualification Required:

• Diploma / BE in Electronics, Mechanical, or Electrical Engineering

Industry Experience:

• Mandatory experience in the automobile industry
• Preference for candidates with wiring harness or auto-component production exposure

This role is ideal for individuals who understand high-volume automotive production environments and seek to contribute to the optimization of manufacturing processes.

Key Responsibilities

As a Production Engineer – Wiring Harness Division, you will be responsible for ensuring smooth and efficient manufacturing operations, particularly on the shop floor. The major responsibilities include:

1. Wiring Harness Assembly & Shop Floor Activities

• Overseeing end-to-end assembly of wiring harnesses
• Managing shop floor activities, manpower, and workflow
• Implementing Kaizen and process improvements
• Ensuring WIP (Work In Progress) and inventory management
• Supporting new project development and introduction

2. Process Efficiency & Productivity Improvement

• Conducting time study, motion study, and line balancing
• Improving productivity through systematic analysis
• Identifying bottlenecks and optimizing process flow

3. Production, Rejection & Approval Reports

• Preparing and submitting daily, weekly, and monthly reports
• Managing production data, rejection percentages, and scrap notes
• Coordinating with quality and engineering teams for first piece approval (FPA)

4. Work Study and Process Optimization

• Applying Time & Motion Study techniques to streamline operations
• Ensuring optimum utilization of manpower and resources
• Supporting lean manufacturing practices

5. Daily Planning & Production Scheduling

• Planning and executing day-to-day production activities
• Coordinating resource requirements and material flow
• Ensuring adherence to planned schedules and targets

6. Problem Solving & Root Cause Analysis

• Identifying and analyzing line problems through RCA
• Implementing corrective actions and countermeasures
• Working with cross-functional teams to prevent recurring issues

This role demands strong shop-floor leadership, technical problem-solving skills, and a continuous improvement mindset.

Candidate Requirements

To succeed in this role, candidates must have:

• Strong experience specifically in the automobile sector
• Hands-on exposure to wiring harness manufacturing (preferred)
• Understanding of lean systems, time studies, and Kaizen
• Ability to prepare reports and manage process metrics
• Strong coordination and communication skills
• Problem-solving approach with attention to detail

Job Location

Mandal Becharaji Road, Jalisana
Gujarat – 382120

This area is a major automotive manufacturing hub with companies like Suzuki, Honda, and tier-1 suppliers. The location offers great exposure and a fast-paced industrial environment.

How to Apply

If you meet the eligibility criteria and want to join Yazaki’s dynamic production team, send your updated CV to the HR department.

📩 Email ID:
Soniya.Mali@in.Yazaki.com

Ensure your subject line is clear and professional:
Application for Production Engineer – Wiring Harness Division

The role of Production Engineer – Wiring Harness Division at Yazaki is a promising opportunity for professionals with strong manufacturing and automotive experience. From process improvement to production planning, this position allows you to work at the core of automotive electrical systems manufacturing.

Top 15 Interview Questions & Answers for Production Engineer – Wiring Harness Division

1. What is a wiring harness and why is it important in automobiles?

Answer:
A wiring harness is a bundled assembly of cables, connectors, and terminals that transmits signals and electrical power throughout the vehicle. It ensures safe and organized routing of electrical circuits, reduces installation time, improves reliability, and prevents electrical failures.

2. What are the critical checkpoints in wiring harness assembly?

Answer:

• Correct wire length, color, and gauge
• Terminal crimp quality
• Connector locking confirmation
• Routing and bundling accuracy
• Continuity and insulation resistance testing
• Proper taping and protection components (PVC, corrugated tubes)

3. What is the purpose of a Time & Motion Study?

Answer:
Time & Motion Study helps analyze each operational step to identify inefficiencies, remove non-value-added activities, balance the line, and improve productivity. It is used to determine standard times and optimize manpower utilization.

4. Explain line balancing in wiring harness manufacturing.

Answer:
Line balancing involves assigning tasks to workstations so that each station has nearly equal workload. It helps reduce waiting time, eliminate bottlenecks, increase productivity, and ensure smooth material flow on the assembly line.

5. What is the First Piece Approval (FPA) process?

Answer:
FPA verifies the first produced piece against design, quality standards, and customer requirements before starting mass production. It ensures correct specifications, avoids defects, and confirms setup accuracy.

6. What steps do you follow to reduce rejection on the shop floor?

Answer:

• Root Cause Analysis (5 Why / Ishikawa)
• Reviewing operator mistakes and retraining
• Improving process parameters
• Enhancing inspection checkpoints
• Strengthening Poka-Yoke mechanisms
• Regular audits and workstation improvements

7. What are common defects in wiring harness manufacturing?

Answer:

• Poor crimping
• Loose connectors
• Wrong terminal insertion
• Wire damage or cuts
• Incorrect taping
• Routing errors
• Continuity failures

8. What is Kaizen? How have you implemented it?

Answer:
Kaizen means continuous improvement.
Example: Improving workstations for shortest hand movement, reducing changeover time, adding visual controls, rearranging materials to reduce motion & improve flow.

9. How do you ensure inventory and WIP are controlled?

Answer:

• Using FIFO and Kanban
• Maintaining material flow mapping
• Daily WIP monitoring
• Coordinating with stores & planning
• Avoiding excess production

10. Explain root cause analysis for a recurring defect.

Answer:
I use tools like:

• 5 Why Analysis
• Fishbone Diagram (Cause & Effect)
• Why-Why tree
  After identifying the root cause, I implement corrective actions such as process changes, training, poka-yoke, or tool modifications to prevent recurrence.

11. What are your responsibilities during daily production planning?

Answer:

• Review previous day’s performance
• Align manpower, materials, and machines
• Set production targets
• Plan based on model mix
• Ensure quality and delivery timelines
• Coordinate with Maintenance, Quality, and Stores

12. How do you handle operator mistakes or deviations on the line?

Answer:

• First stop and contain the issue
• Identify cause (training, fatigue, unclear instructions)
• Provide immediate correction
• Retrain the operator if required
• Add checks, SOP updates, or Poka-Yoke to prevent recurrence

13. What is your experience with Poka-Yoke?

Answer:
Poka-Yoke is mistake-proofing.
Examples implemented:

• Connector orientation guides
• Color-coded terminals
• Wire length fixtures
• Auto-cut machines with error alarms
  These prevent assembly mistakes and ensure consistent quality.

14. How do you monitor daily scrap and rejection?

Answer:

• Track daily scrap quantity and reasons
• Compare against targets
• Conduct daily rejection analysis
• Implement corrective actions
• Report to management with trends and improvements

15. Why should we hire you for the Production Engineer role?

Answer:
Highlight:
“I have hands-on experience in automotive wiring harness production, strong understanding of line balancing, process optimization, Kaizen, and quality systems. I’m committed to continuous improvement and can contribute to productivity, quality, and efficiency from day one.”