Wiring Harness is a "multi-process assembly", and any small mistake may be exposed after the entire vehicle/equipment is assembled, causing rework and line shutdown.The following is a summary of the most common types of problems on site, and executable improvement methods are given.

1) Poor crimping (virtual pressure, pull-off, wing deformation)

Typical manifestations: insufficient pulling force, uneven coverage of terminal fins, exposed or broken conductor wires, and drift in crimping height.

Suggestions for improvement: Confirm terminal/wire gauge matching; perform regular maintenance on the crimping mold; tension/section must be done on the first piece and batch change; establish dual indicators of "crimping height + tension"; and work station matching to prevent foolproofing (terminal direction, wire length positioning).

2) Insertion errors (misplaced, missed insertion, not fully inserted)

Typical symptoms: wrong pin position, lock is not in place, secondary lock is not locked, pin is retracted.

Suggestions for improvement: use tooling plates and color/number identification; take photos and record or barcode traceability of key plug-in points; add touch confirmation and visual windows for "insertion in place"; install terminal anti-return buckles when necessary.

3) Insulation/exterior damage (skin breakage, crushing, cuts)

Typical causes: mismatching of peeling blades, over-tightening of cables, friction at corners, and assembly space interference.

Suggestions for improvement: Lock and check the parameters of the peeling machine; add sheaths/bellows at corners and through holes; design the wiring harness direction according to the "minimum bending radius"; increase the frequency of process inspections for vulnerable points.

4) The waterproofing is not in place (the sealing ring is installed incorrectly/missingly)

Typical symptoms: Seal rings are misaligned, flattened, and mismatched in size, leading to water seepage; rubber plugs are not inserted in place.

Suggestions for improvement: Partition management of seals and anti-fool boxes; 100% visual/gauging confirmation after assembly; air tightness/rain verification of key circuits; batch changes of seals require re-confirmation of size and hardness.

5) Continuity/insulation test abnormality

Suggestions for improvement: Clean and replace the test needle bed regularly; conduct three-dimensional tests of continuity/short circuit/insulation; perform "Pareto analysis" on frequent NG items, and push the problem back to the specific process and man-machine material method loop.

Conclusion

To reduce the defect rate of Wiring Harness, the most effective method is not to "add final inspection", but to move key risk points forward into the process, and achieve stable output through foolproofing, first article verification, process inspection and traceability systems.

Statement: This article is a summary of technical knowledge and experience. The specific parameters and processes are subject to actual project requirements.