Automotive Wire Harness Production Processes - Miracle Electronics

1. 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

2. 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, (https://www.miracle.net.in/blog/cant-complex-cable- assemblies-fully-automated/). While 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 this is not so

3. 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 today’s 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

4. certified and approved by DGAQA and MSQAA for platform specific applications. For more Information: https://www.miracle.net.in/