With wire harnesses being used across many industries, manufacturers must implement effective quality assurance strategies to ensure product reliability and drive continuous improvement.
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The key challenge is integrating quality control seamlessly into the manufacturing process. This guide will explain what wiring harness quality assurance involves, why it matters, and how to assess it effectively.
Quality assurance processes help manufacturers ensure wiring harnesses are fully operational, safe, and reliable.
Wiring harnesses are used in critical applications, where faults can cause electrical failures or fire hazards. Thorough quality assurance at each stage helps manufacturers detect issues early and ensure long-term performance and safety.
Wiring harnesses must comply with strict industry standards and regulations. The primary consideration for manufacturers is where the wiring harness will be used.
Regulatory and safety standards tend to be regional. For instance, wiring harnesses designed for North American markets must adhere to guidelines and rules set by the Underwriters Laboratories (UL) or the Canadian Standards Association (CSA).
Likewise, many territories feature installation standards specific to their countries. A large segment of these areas bases their guidelines on regulations set by:
Manufacturers must aim to limit the environmental impact of their processes and products. Two regulations are most concerned with this: the European Union’s Registration, Evaluation, Authorization, and Restriction of Chemicals (REACH) and Restriction of Hazardous Substances (RoHS).
Manufacturers must comply with these directives and the UK’s Waste Electrical and Electronic Equipment (WEEE), which provides guidelines on how electronic components and devices should be broken down, recycled, and disposed of.
The IPC/WHMA-A-620 is the benchmark for assembling wire harnesses. It is the primary guideline for wiring harnesses intended for U.S. markets. Under the intended application, cable assemblies may also be required to meet additional connection standards and specifications, such as:
It’s also common for assemblies to undergo review and testing by independent third-party services like the ETL.
Note: These standards can only be met by manufacturers who implement and maintain high wiring harness quality assurance standards.
Quality assurance makes troubleshooting and fault detection much easier. This, in turn, saves time and reduces excess material consumption, enhancing sustainability.
When implementing a quality assurance strategy, manufacturers often must evaluate their entire approach to production. To do this properly, they must observe five key areas.
Traditionally, DFM’s main goal was to ensure that the final product would function well and meet performance requirements. DFM has expanded its focus to include other manufacturing process parameters like cost, efficiency, and complexity.
Manufacturers could streamline assembly, reduce errors, and improve the overall reliability of products by simply optimizing the wiring harness design.
Although the manufacturing process can vary significantly, manufacturers should plan multiple standardized processes to accommodate these differences. For example, more steps are required to produce braided wire harnesses than their non-braided counterparts. Further, they typically need different testing measures.
Manufacturers can track the various steps and requirements by recording them in clear, well-written documentation. They should also implement monitoring systems, which should flag any activity that strays away from the documented processes and rules.
Manufacturers can detect and fix errors by comprehensively testing wiring harnesses.
Before starting production, manufacturers check wires and other components for materials, gauge, connector damage, and terminal space. If any of the products look unsatisfactory, they ask for replacements.
Manufacturers create a real-world demo product to test the real-world viability of a wiring harness design. This can identify flaws and assess whether the design is fully optimized for manufacturability.
This process includes inspection and testing at multiple stages of manufacturing. Manufacturers work closely with the customer’s engineering team to perform the required tests. High-quality testing equipment is essential, as it affects both accuracy and efficiency. Technicians follow specifications and custom drawings to minimize errors.
Each harness undergoes a thorough visual inspection to verify physical dimensions, workmanship, labels, and electrical properties. Upon request, manufacturers conduct high-potential tests and continuity tests on 100% of the manufactured harnesses. Additionally, some typically construct a wire harness mate to ensure precise alignment with the customer’s specifications, facilitating accurate electrical testing based on their drawings.
Note: Manufacturers can hire an independent entity specializing in wire harness testing. This would fill in any inspection or testing gaps that the manufacturer missed.
Manufacturers must update workers at all levels on the latest procedures.
Note: More technical employees are supposed to be IPC/WHMA-A-620 REV C certified.
During the wire processing process, steps can be automated, making the process easier and more efficient.
Fully automated wire processing machines and benchtop equipment can cut, strip, and terminate ribbon cables, battery cables, coax cables, and FFC cables.
With completely automated wire processing machinery, we can cut, strip, and terminate both ends of a wire at rates of up to 10,000 wires per hour.
You can apply automation when crimping terminals and plugging in wires already fitted with end terminals into the connector housing. You can also solder wire ends via automation.
Wiringo performs millions of crimps per year. We use automatic wire processing equipment, hand tools, benchtop equipment, and hydraulic and pneumatic presses to crimp terminals.
In the wire processing industry, authentication is important.
At Wiringo, we employ four wire marking methods.
After every job, a complete electrical continuity test ensures no open, short, or faulty wiring. The testing step is slightly automated since you’ll use a teddy board designed for the wire harness, allowing it to plug into the board and check for any electrical malfunctions.
Key indicators for evaluating a manufacturer’s wire harness quality assurance capabilities include:
Various certifications can show a manufacturer’s competency and dedication to quality assurance. These certificates indicate that the manufacturer complies with recognized industry rules and regulations, and they can be used to gauge the manufacturer’s trustworthiness.
Wiringo is rigorously certified, such as ISO for general quality control and IATF for automotive quality.
A manufacturer with a long track record will likely have a strong reputation for wiring harness quality assurance. Their experience often means they have the tools and expertise to execute your design and ensure its quality.
As mentioned in the previous section, some regulations, like REACH, require manufacturers to source materials only from REACH-compliant manufacturers. Regardless of whether they aim to be REACH compliant, manufacturers must source all raw materials from reputable industry-recognized suppliers.
Wiringo prides itself on sourcing materials from trusted RoHS-compliant suppliers. Over the last few years, we have established strong strategic partnerships with many global component suppliers. Some notable examples include Future Electronics, Arrow Electronics, and Element 14. Our purchasing department balances cost with quality.
Many manufacturers prominently feature past customer testimonials and reviews on their websites. It’s important to take the time to read some of these reviews. It’s also vital that you search for reviews from third-party sources. You can find client interactions and reviews on social media sites like Facebook, YouTube, and Reddit.
With over ten years of experience in the industry, Wiringo leverages the latest precision equipment and specialized manufacturing techniques to deliver wiring harnesses with quality assurance. Our Outgoing Quality Control (OQC) department performs comprehensive testing featuring cross-section analysis, 100% online, and IEC spotting tests.
Wiring harnesses (AKA cable harnesses or wire assemblies) are an arrangement of bundled wires, cables, and connectors. Their primary purpose is to neatly package, sort, and secure the cables that transmit electrical and digital signals to systems and devices.
Wire harnesses typically consist of the following components:
Wire harnesses have found extensive usage in motor vehicles. For instance, they connect the vehicle’s Engine Control Unit (ECU) to its many sensors and actuators. This allows for precise control of the engine’s performance.
As electric vehicles (EVs) become more common, the world is likely to see more intricate cable networks in motor vehicles that rely on wire harnesses.
Bundling multiple wires and cables into a unified construction leads to easier installation. Hence, the use of wire harnesses can substantially reduce the time it takes to set systems up.
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Wiring harnesses can positively impact the reliability of devices and systems by:
Several industries benefit from using wiring harnesses. For instance:
The wiring harness design elements are determined by their application. However, there are basic components that all wire harnesses share.
These are essentially the (electrically) functional components of the cable assembly. They consist of wires (conductive elements), insulation, and optional shielding.
Copper or aluminum typically comprises the wires while PVC, Teflon, or polyurethane comprises the insulation. Shielding in wiring harnesses and cables provides protection from electromagnetic (EMI) and/or radio frequency interference (RFI).
Connectors join electrical circuits together. Depending on the type, they can connect cables, other harnesses, or systems. There are two main types of connectors:
Terminals can be supplementary or serve as alternatives to connectors. They’re endpoints that connect wires to components or devices. They come as either crimps or solder at the ends of wires.
Cable management components allow manufacturers to sort and bundle wires. This includes:
For effective cable routing and management, you must first extensively plan your layout. Separate power cables from data cables to avoid interference. It’s best to map the cable routes and identify the shortest and most efficient pathways.
Avoid sharp bends and kinks as they may lower the signal integrity and lead to damage. Even the distribution of cables will allow you to avoid intense stress on single points.
Be careful not to overload conduits and cable trays. Each cable should have ample space to prevent wear and overheating.
Protective sheathing (AKA cable sheathing or cable jacket) allows the wire harness to guard cables from environmental factors, abrasions, vibrations, and impacts. It also provides added electrical insulation and makes cables easier to bundle.
Common materials for protective sheathing include:
The individual wiring harness components work together to create a reliable and efficient structure. How well each component functions is dependent on the following factors.
The materials you use will impact the durability and overall performance of your wire harness. When selecting materials, it’s important to do so on a case-by-case basis where you consider the following:
MRI machines are an example of medical equipment that require reliable wiring harnesses. They must produce accurate imaging while being safe for patients. Consequently, an MRI machine’s wiring harness must be able to tolerate high temperatures, EMI, and mechanical stress.
The component material types significantly impact the integration of wiring harnesses. Fundamentally, the wiring harness’s materials must be compatible with those of the cables (wires).
Copper tends to be the best choice for wires because it is highly conductive and also offers excellent compatibility with many insulation and sheathing materials. For example, PVC and polyethylene are resistant to a wide range of chemicals.
Quality Assurance (QA) enables manufacturers to ensure the reliability and performance of cable assemblies. By pre-assembling and testing, ensures that each wiring harness part functions as it should and meets quality standards before it is integrated.
For instance, WellPCB’s QA processes include:
In addition to the above processes, WellPCB adheres to the following standards and certificates:
The industry has seen a wide range of exciting trends and advancements in wiring harness component design.
Polymers and composites such as Poly-ether-ketone-ketone (PEKK) can withstand extreme temperatures. High-resistant materials such as these reduce the risk of melting and fire. This makes them ideal for wire harnesses that will be used in aerospace, the automotive industry, and industrial environments.
The Internet of Things (IoT) will also reshape how we manufacture wiring harnesses. Smart materials and components can monitor and report the health of the harness. Self-healing polymers and conductive inks have the potential to increase the durability and lifespan of wire harnesses.
The use of lightweight materials and miniaturization will allow us to develop more space-efficient and lighter cable assemblies. 3D printing is reshaping the manufacturing industry as a whole. Additive manufacturing will allow manufacturers to produce wiring harnesses with more intricate designs. It will also potentially reduce waste and decrease costs.
There’s also been an industry-wide drive to produce more environmentally friendly and sustainable wire harnesses. By leveraging biodegradable insulation materials and recycled metals, we can reduce the environmental impact of wire harnesses.
Now that you’re informed on the basics, how do you choose the right components for your application?
As we previously mentioned, different industries and applications have unique requirements. For instance, the automotive industry requires wiring harnesses with exceptional durability, high vibration resistance, and the ability to withstand high temperatures.
This is because these wire harnesses will connect electrical components of vehicles such as lights, sensors, and control units. As such, the fabrication of these wiring harnesses must adhere to the ISO and IATF standards.
On the other hand, the aerospace industry requires wiring harnesses with lightweight materials that are still reliable and resistant to extreme temperatures and EMI. These wire harnesses need to be able to power avionics, communication systems, and control systems in aircraft. They need to meet the AS’s strict standards.
Strategies such as modular design can make integration more seamless and efficient. Modular design involves creating smaller harness sections that can function independently. This technique simplifies the assembly process and makes wire harnesses easier to maintain. Moreover, it allows for easier upgrades, repairs, and replacements.
You can increase the compatibility of your wire harness by sticking to standardized parts. Using custom wiring harness parts makes it harder to source replacements for damaged components and complicates inventory management. You can address these issues and ensure consistent quality by using standardized components.
Another way to ensure cohesion and make integration easier is by using color coding and labeling. This makes it easier to identify and organize components. If you perform them correctly, color-coding and labeling can decrease the potential for errors, speed up installation, and ease repair and maintenance.
WellPCB is a name you can trust in sourcing and manufacturing wiring harness components. We offer a comprehensive selection of services and capabilities.
WellPCB utilizes the latest technology to bring your designs into reality. We use the latest automated wire-cutting and stripping machinery to precisely shorten your wires to specification.
These are not the only wire processing tasks our machines can handle. They can also crimp, solder, and add termination to the wires. This ensures high accuracy and consistency and reduces manufacturing errors. We also bend and form, tie and label, splice, and produce sleeving and tubing for insulation.
WellPCB performs comprehensive testing at multiple points of the manufacturing cycle. Our partnerships with Amphenol, JST, Molex, and Tyco Connectivity give us access to a reliable supply chain for raw materials.
WellPCB specializes in custom wiring harnesses. We cater to various industries such as medical, automotive, telecommunications, and consumer electronics. Our highly experienced team handles the entire process from design to sourcing, and performing the final assembly process.
Compatibility and quality assurance are important to us. That’s why we implement such stringent testing and inspection protocols.
When you partner with WellPCB, your wiring harnesses will undergo stringent visual inspection. During this inspection, we systematically examine their design and structure, looking for flaws or damage to the integrity of the wires, connectors, and sheathing.
In addition to the tests and inspections, we also perform dimensional measurement, continuity, high potential, and failure probs.
WellPCB holds and adheres to the following standards and certificates:
The above article essentially proves that wire harnesses are greater than the sum of their parts. However, you must choose components that will best meet the demands of an application as well as work well with the other components of the wire harness. This is the best way to ensure that your wiring harnesses perform optimally and are durable. Another way is to select a reputable and reliable manufacturer. WellPCB is this manufacturer. Contact us today to learn how we can help you build high-performing wiring harnesses.
The main components of the wiring harness are the cables, connectors, protective sheathing, and cable management parts.
Connectors and terminals bridge different sections of the wiring harness and also connect the wiring harnesses to other devices and systems.
The most commonly used insulation materials include PVC, Teflon, Silicone, Polyethylene (PE), rubber, and LSZH (Low Smoke Zero Halogen).
Shielding in wire harnesses ensures that signals within the wiring harness remain unimpeded from any outside interference, ensuring reliable data transmissions.
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