Automotive Wire Harness Production Processes - Miracle Electronics

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Automotive Wire Harness Production Processes -
Miracle Electronics There was a time when every
household had only one scooter that was used by
the head of the family, with everyone else
relying on him for transport and cars were
owned only by the rich upper class families. But
today, with the increasing facilities of EMI,
purchasing vehicles has become so easy. In fact,
today, every household has as many two wheelers
as there are members in the family, and also at
least one car. With the increasing demand of
such automobiles, there is also an increasing
production of such vehicles. Moreover, newer
models of vehicles are coming up every now and
then, with newer technologies and complexities.
To serve all these requirements, electrical wire
harnesses are being largely used.
With so many such harnesses within a single
vehicle, the number of signals that need to be
passed by the harness also increase, as well as
the complexities. Every harness used needs to
cope with a variety
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of sensors, networks, and power connections. And,
in case of any special customizations, countless
configurations may need to be supported and
tracked. This is why it is important that
standard procedures are followed to build
genuine wire harnesses. Automotive wire harness
production process First, the design is made,
after which the formboard is designed, followed
by production modules and sub-assemblies, which
sometimes require their own assembly board. Then,
the bill of process is designed, allocating
wires, twists, splices, and all remaining
material to its designated equipment or work
station. The bill of process is then released
into the enterprise resource planning system,
which is followed by balancing and optimizing the
final assembly carousel, and then the creation
of work instructions. Automotive wire harness
production automated or manual? You may think
that with everything becoming so advanced and
automated today, the process of wire harness
manufacturing may also be automated. But, this
is not so (https//www.miracle.net.in/blog/cant
-complex-cable- assemblies-fully-automated/). Whi
le there are certain procedures that can be
automated in the process, manual processes are
majorly used for many intricate processes. This
makes wire harness manufacturing a labourious
and time-consuming task. In fact, 85 of wire
harness production processes are till date carried
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out by hand, leading to a high potential for
error, which can be detected only during the
final assembly. Apart from errors, this may also
lead to delays, which can largely affect
high-pressure new- production introduction
phases. Which approach should be used to
manufacture wire harnesses? In todays digital
world, companies create a digital thread, in
which all the functions from architectural and
functional design to physical design to
manufacturing and engineering to after sales
service can use the same data. The same data
model can be used at each stage of the wire
harness lifecycle, which can help make decisions
for every other domain. With the help of such a
digital thread, it becomes possible to support
the many manual and automated processes that are
used in wire harness manufacturing and
assembly. To conclude, we can say that a
model-based engineering approach with a
continuous digital thread can help manufacturers
reduce design errors by 50, and designing time
by 85, and production time by 30. You must
thus approach such wire harness manufacturers in
India who use these advanced methods to bring
about faster production times, and least possible
errors. Miracle Electronics is one such
manufacturer who uses the best production
processes that are certified for quality to ISO
9001, AS9100C. Also, the quality of wire
harnesses manufactured here are
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certified and approved by DGAQA and MSQAA for
platform specific applications. For more
Information https//www.miracle.net.in/