Lead Assembly Technician

Job Description

Job Description

The Lead Active Part Assembly Technician is responsible for leading active part assembly operations for liquid-filled distribution transformers in accordance with engineering drawings, work instructions, process requirements, and quality standards.

The main focus of this role includes positioning and securing coils to the core, upper yoke assembly, coil wedging using specialized insulation materials, and connection of internal coil leads required to complete the active part assembly.

This position is intended for experienced manufacturing personnel who will serve as part of the seed team during facility ramp-up, supporting process stabilization, operator training, equipment readiness, and production quality. The role is expected to lead workmanship standards, reinforce assembly discipline, and support consistent execution of active part assembly operations.
Active Part Assembly Operations

• Lead active part assembly operations for liquid-filled distribution transformers in accordance with engineering drawings, bills of material, and work instructions
• Position and secure coils to the transformer core using approved methods, tools, fixtures, and assembly practices
• Perform upper yoke assembly, including installation and alignment of the top section of the core after coils have been placed over the core limbs
• Install coil wedges and specialized insulation materials required to secure coils against the core and maintain assembly stability
• Verify active part fit-up, alignment, and assembly readiness throughout the build process
• Support development and refinement of standard work and best practices for active part assembly operations during ramp-up

Internal Lead Connection

• Route, position, secure, and connect internal coil leads in accordance with engineering drawings and work instructions
• Verify lead placement, routing, clearances, and connection conformance throughout the active part assembly process
• Ensure internal lead connections are completed in a manner that supports assembly integrity, insulation protection, and downstream manufacturing requirements
• Identify lead-routing or connection issues and take corrective action in accordance with standard procedures

Quality Control & Inspection

• Inspect core components, coils, insulation materials, wedges, leads, hardware, and related materials prior to use for condition, completeness, and conformance
• Verify coil positioning, upper yoke alignment, wedging condition, lead routing, and overall active part assembly integrity throughout the build process
• Perform in-process dimensional and visual checks using standard measurement and inspection tools in accordance with work instructions
• Identify defects such as poor fit-up, damaged insulation, improper wedging, lead-routing issues, missing hardware, or non-conforming assembly conditions and take corrective action
• Accurately log production data, material traceability, and quality yields into the ERP or production tracking system
• Identify recurring assembly or quality issues and support corrective actions to improve consistency and reduce rework

Material Handling

• Safely handle cores, coils, active part components, insulation materials, wedges, leads, hardware, and related materials using appropriate lifting or handling equipment
• Use overhead cranes, hoists, fixtures, and other approved devices as required
• Stage materials and assembly aids to support efficient workflow while maintaining organization and traceability

Tools, Equipment & Workplace Standards

• Use hand tools, power tools, fixtures, assembly aids, and related equipment required for active part assembly operations
• Perform routine equipment and tool checks and report issues as needed
• Support troubleshooting of equipment, tooling, or process issues as required
• Maintain a clean and organized work area in accordance with company standards

Training & Team Support

• Support training and qualification of new operators during factory ramp-up
• Share active part assembly best practices, workmanship expectations, and quality standards with team members
• Assist supervisors in identifying process gaps, training needs, and improvement opportunities
• Interface with upstream winding, core preparation, and downstream tanking/final assembly operations as required by production flow

Required Qualifications
Education

• High School Diploma or GED required

Experience

• 5+ years of experience in a manufacturing, industrial, or assembly environment
• 3+ years of experience in transformer active part assembly, transformer pre-assembly, core and coil assembly, or similar heavy electrical manufacturing environments
• Prior experience supporting equipment readiness, process stabilization, or operator training in a quality-critical manufacturing environment preferred

Skills

• Ability to read and interpret technical drawings, work instructions, bills of material, and production documentation
• Ability to perform active part assembly operations in accordance with approved procedures and workmanship requirements
• Ability to route, position, secure, and connect internal coil leads in accordance with engineering requirements and work instructions
• Proficiency with measurement and inspection tools such as tape measures, calipers, gauges, and related inspection tools
• Strong mechanical aptitude and attention to detail
• Demonstrated ability to identify, troubleshoot, and respond to assembly, fit-up, insulation, lead-routing, or quality issues
• Ability to support startup, training, and process stabilization activities in a manufacturing environment

Safety & Certifications

• Experience with overhead cranes, hoists, or lifting equipment preferred
• Ability to follow all workplace safety requirements and reinforce safe work practices with others
• Ability to safely work around heavy components, insulation materials, assembly fixtures, and moving equipment

Preferred Qualifications

• Associate degree (AAS) in Electrical Technology, Mechanical Technology, Mechatronics, Industrial Technology, or related field strongly preferred
• Experience in liquid-filled transformer manufacturing or similar heavy electrical manufacturing environments
• Experience with core and coil assembly, upper yoke assembly, coil wedging, insulation placement, or related active part manufacturing operations
• Experience supporting process improvements, operator training, startup activities, or process documentation in a quality-critical environment
• Demonstrated ability to lead by example in quality, safety, and execution

Additional Requirements

• Ability and willingness to travel Internationally for training, or support activities, including extended travel during initial facility ramp-up
• Must be legally authorized to work in the United States
• Ability to meet the physical requirements of the role as outlined below

Physical Requirements

• Ability to stand for extended periods during the work shift
• Ability to lift, carry, and move materials weighing up to 50 lbs, with or without assistance
• Ability to perform repetitive tasks involving hand and arm motion
• Ability to bend, reach, climb, and work in a manufacturing environment around moving equipment
• Ability to safely work in an industrial environment using required personal protective equipment (PPE)

Work Environment

• Industrial manufacturing environment
• Exposure to cores, coils, insulation materials, wedges, hardware, hand and power tools, lifting devices, and moving equipment
• Requires standing, lifting, and repetitive manufacturing and assembly-related tasks