Wire Harness Processing Flow Explained

Different wiring harness factories may have different process names, but they will not deviate from the following main process nodes, which are: incoming material inspection and storage, offline, crimping, sub-packaging, assembly, inspection (appearance/size/electrical inspection) and packaging. Each process has input and output, that is, relevant documents need to be prepared to guide the production of the corresponding process.

-------------------------------------------------------------------------------------------------

The offline list is the offline and crimping detailed list, which contains a variety of process parameters and requirements. In the production process of wire harness, the off-line table Z finally passes through the blanking and crimping process card, which is used to guide the operation of the off-line crimping process and guide the workshop production process. Every process also needs to be inspected. Only after the inspection is passed can batches be carried out, and the process needs to be monitored at any time. For example, in the off-line process, the first piece needs to be made first, and the parameters such as line length and peeling of the first piece pass the inspection before batch off-line can be carried out. Off-line (blanking) process definition: Off-line is the process of cutting, stripping and bundling wires of different specifications according to the length, color, wire and wire diameter of the process documents according to the design drawings. Process: prepare materials → adjust equipment → first item inspection (measure line length, stripping) → hand over to QC inspection → mass production (100% self-inspection in middle and final inspection) → sort out wires → put in turnover truck or turnover box → Waiting for turnover. Inspection: In the off-line process, it is necessary to measure the process parameters such as line length, full stripping head and half stripping head length, opening length, etc. (ruler, vernier caliper). Semi-automatic fully automatic short-circuit crimping process definition: Crimping is the process of bringing wires and terminals together. Process: Prepare materials → adjust equipment → make first piece → first piece inspection (micrometer measurement of crimping height, crimping width, tensile test and inspection) → mass production (100% self-inspection of crimping quality in the middle and final inspection) → put in the turnover box or turnover truck to be turned around. Inspection: In the crimping process, it is necessary to measure whether there is R angle, whether the visible range of the core wire and insulating skin is within the tolerance range, whether the core wire pressing part and the insulating skin pressing part are damaged, and the crimping twist. Definition of sub-packaging process: Sub-packaging is the process of assembling off-line or crimped semi-finished products into new semi-finished products with sheaths, PVC pipes, corrugated pipes, glass fiber pipes, rubber parts and other parts. (The sub-packaging drawing of the process design calculates personnel according to work stations and working hours), and it is also divided into centralized sub-packaging and online sub-packaging. Process: Prepare all the materials → one insert, two listens and three pulls → install self-locking. Inspection: Self-inspection is completed according to the process of one insertion, two listening and three pull-back. Final assembly process Final assembly is the process of combining off-line or crimped semi-finished products and sub-packaged semi-finished products with other materials into finished wire harness products (Note: during the assembly process, pay attention to the branching direction, the length of the wire harness, whether the PVC tape is wrapped qualified, and whether the wire harness is wrapped according to the requirements of the tooling board). Adhesive tape or cable ties are bundled into bundles, which is the wire harness. Inspection process The inspection process mainly includes appearance inspection, installation accessory inspection, dimension inspection, 100% electrical inspection and image inspection. 100% electrical inspection and appearance, size, and branch direction inspection need to be carried out for each finished product. Image inspection is also required. It mainly detects the wiring harness with the fuse box to determine whether the fuse and relay plug-in position are correct. It also needs to detect the torque of bolts in the fuse box.

---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- If you have related [connector wiring harness and cable products] purchasing/purchasing needs or want to purchase/understand which connector wiring harness and cable product solutions we can provide, please contact our business staff below; If you have related [Connector Wiring Harness Cable Products] sales/resources and promotion needs, please click "→ Business Cooperation ←" to negotiate with a dedicated person!