wire harnessWiring harness assembly must be executed with extreme care. Any defect in the production process results in overall failure, leading to unexpected incidents. Nonetheless, it has been noticed that, manufacturers commit some common mistakes when assembling wire harnesses.
Here, in this blog, the six basic mistakes perpetrated by a wire harness manufacturer are listed.

The 6 Manufacturing Defects

Ensure that you never do the following when assembling wire harnesses.

  1. Preparing Wires – It has to be carried out with sheer care and precision as it determines the overall efficiency and performance of the assembly. Many of the manufacturers go wrong in this very first stage by selecting wrong wires that are cut and stripped at the ends indecorously.
  2. Not Following the Assembly Drawing – A lot can go wrong when connecting the wires in the chassis. Wiring harness manufacturers usually commit the mistake of connecting the wires erroneously. This fails the wire assembly, and in turn the entire system. Follow the assembly drawing stringently to avoid such mistakes.
  3. Defects in Crimping – The crimping process, which involves terminating the wires in a harness, is the most critical step in the wire harness assembly. If not executed properly, it results in open or short circuits. Many of the manufacturers execute this haphazardly, leading to catastrophic incidents.
  4. Improper Soldering – This is yet another major area where manufacturers commit mistakes. Improper soldering of wires to terminals leads to thermal damage. Use the right soldering equipment, and proper soldering temperature when performing this task.
  5. Missing Wires, and Using Wrong Hardware – To meet the project schedule, some wiring harness manufacturers may tend to overlook wires that are crucial in the assembly. This could result in the failure of the wiring harness assembly. Also, the manufacturer may use the wrong hardware, including stand offs, clamps, washers or screws to assemble the harness.
  6. Improper Wire Tying –– The last step in the wiring harness assembly process is tying the wires, utilizing plastic tie wraps. Sometimes, wire harness manufacturers tie the wraps too tight to an extent that it damages the wires. On the other hand, if it is tied loose, there are chances of it not holding the bundle properly. Hence, the manufacturers must ensure that the ties are tightened around the wires in the right manner.

If the above mentioned mistakes can be avoided, along with taking care of other assembly specifications, manufacturers can assemble the harness to customers’ requirements. Double-checking the process helps eliminate aforementioned defects, producing superior quality wiring harness.

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