The Senior Technician – Control Panels & Test is responsible for the assembly, wiring, testing, and troubleshooting of custom control panels, electromechanical assemblies, and cable/harness systems using Cirris and other automated test equipment. This role provides technical expertise on panel builds and electrical testing, supports production and engineering with test development, trains and mentors technicians, and ensures all products meet customer specifications, engineering drawings, and industry quality standards.
Key Responsibilities
- Assemble, wire, and terminate control panels, enclosures, and electromechanical assemblies according to electrical schematics, panel layout drawings, and customer specifications.
Set up, program, and run Cirris (and comparable) continuity, hipot, and functional test equipment; build and maintain test fixtures and test lists/programs for new and existing assemblies.
- Perform continuity, resistance, insulation resistance, dielectric withstand (hipot), and functional testing on control panels, wire harnesses, and cable assemblies.
Troubleshoot wiring, component, and connectivity issues down to root cause; implement and document corrective actions.
- Review electrical schematics, panel layout drawings, wiring diagrams, and bills of materials (BOMs) for accuracy, manufacturability, and testability, and flag discrepancies to engineering.
Support prototype builds, new product introductions, and first-article inspections for new control panel and test programs.
- Train and mentor technicians and assemblers on panel wiring practices, test equipment operation, workmanship standards, and safety procedures.
Monitor production quality and ensure compliance with IPC/WHMA-A-620, UL 508A (where applicable), and company quality requirements.
- Drive process improvements in panel assembly and test methods to increase throughput, reduce defects, and improve first-pass yield.
Maintain test equipment, fixtures, hand tools, and calibration schedules to keep systems audit-ready.
- Collaborate with engineering, quality, and production teams to resolve technical issues and support design-for-test initiatives.
Support inventory control by verifying components, wire, terminals, and panel hardware against BOMs.
- Ensure compliance with workplace safety policies, lockout/tagout, and electrical safety practices (e.g., NFPA 70E awareness).
Qualifications
Required
High school diploma or equivalent; technical/electrical certification preferred.
- 5+ years of experience in control panel wiring and electromechanical assembly, or wire harness/cable assembly manufacturing.
Hands-on experience with Cirris or similar automated continuity/hipot test systems, including building and editing test programs.
- Strong ability to read and interpret electrical schematics, panel layout drawings, wiring diagrams, and assembly drawings.
Experience with wire processing equipment, crimping tools, soldering equipment, and hand-held test/measurement equipment (DMM, hipot, megohmmeter).
- Knowledge of IPC/WHMA-A-620 standards and electrical assembly best practices.
Proficiency in troubleshooting electrical, wiring, and connectivity issues to root cause.
- Strong organizational, communication, and leadership skills.
Preferred
IPC/WHMA-A-620 Certification.
- UL 508A panel shop experience or familiarity with UL panel build requirements.
Experience with aerospace, automotive, medical, military, defense, or industrial control panel and harness applications.
- Lean Manufacturing or Six Sigma experience.
Familiarity with ERP and manufacturing/test data software systems.
Physical Requirements
- Ability to sit or stand for extended periods.
Frequent use of hand tools, crimpers, cutters, and electrical test equipment.
- Ability to lift up to 40 pounds.
Strong manual dexterity and attention to detail for precision panel wiring and testing.
This position plays a critical role in ensuring the production of high-quality, fully tested control panels and electromechanical assemblies that meet customer requirements, delivery schedules, and industry standards.