What Are the Common Problems in the Wiring Harness Manufacturing Process?

       The Wiring Harness manufacturing industry is based on raw materials such as cables/connectors/plastic parts and tapes. The key technology is stripping, cutting, terminal making, and then adding welding, crimping, heat shrinking, foaming, and visual inspection. The automotive wiring harness designer will use CAN (Controller Area Network-BUS) bus technology to complete the routing and production drawings according to the vehicle electrical distribution, including formal floor plans and 3D assembly diagrams, and then give them to the wiring harness manufacturer. The wiring harness manufacturer will then make and confirm the tooling board drawings according to the customer's drawings, and then the factory can start production.

 

At present, there are several common problems in the production and manufacturing process of wiring harnesses within the factory.

 

1. Wrong plugging means that the wire with the terminal is inserted into the wrong connector hole. For example, it should be inserted into hole No. 1, but the employee mistakenly inserted it into hole No. 2 next to it, which will cause the function to be ineffective, which is a serious mistake;

 

Generally, the corresponding parts of the tooling board will have clear diagrams to tell employees what color wire should be inserted into which hole. In addition, employees will not make mistakes if they work according to the safe operation procedures; this type of incorrect error is mainly for new employees and accelerated production. Training must be strengthened and protective measures must be formulated. There is also an electrical test bench in the last step, so there is generally no need to worry too much.

 

2. There are many processes inside the factory when the connector or fuse box is damaged. It is necessary to set node supervision in advance to collect data to see at which step the error occurs, and then analyze and formulate measures; generally, it is damaged during the incoming materials and transportation.