1. Error prevention technology

Error prevention technology refers to any device or facility that can prevent human error or detect errors at a glance. Then, the error prevention technology is used in the process of wiring harness manufacturing. It is an effective means to avoid wiring harness manufacturing errors through process error prevention design and tool error prevention design. Learn and discuss with you according to different wiring harness manufacturing processes, combined with the application of error prevention methods in practical work.

2. Anti-error design of tangential crimping process (anti-error of MES system)

Tangential crimping technology is a high automation technology in automotive wiring harness manufacturing. Most wiring harness factories in our country operate with automatic tangent crimping equipment. Therefore, tangential crimping is a process with low probability of manufacturing errors.

Manufacturing errors are usually the improper use of wire, terminal, waterproof bolt materials, resulting in the repair or scrap of semi-finished products. The use of wiring harness MES in the switch of different Kanban, to prevent errors, sound scanning error, image alarm, can effectively prevent material misuse.

3. Anti-error design of semi-automatic crimping process (CFM pressure monitoring system)

For some extreme wiring harness, too short or pressing, riveting, with waterproof plug automata can not be crimped, can only rely on semi-automatic machine manual crimping. For the low level of automation, this process is mainly manual operation, including manual threading bolts, heat shrink pipe, closed PVC pipe and other operations are also a process with more manufacturing errors.

Using MES system parameter data to automatically communicate to ACM software system of automata, without manual intervention, through reasonable process error prevention design and application of error prevention tools, can effectively prevent the occurrence of manufacturing errors.

4. Anti-error design of pre-assembly process

The pre-assembly process of automotive wiring harness processing includes two operating modes: online pre-assembly according to order batch and product model centralized area line. In the design process of pre-installation process card, besides considering the time rhythm of pre-installation operation, the process error prevention design of pre-installation operation should be considered.

5. Anti-error design of final assembly process

Automotive wiring harness assembly process is basically divided into two types: single board assembly operation and assembly line assembly operation. Generally, for small-batch models, centralized preassembly and assembly operation is adopted, and then the preassembled semi-finished products are moved to the final assembly area, and a single final assembly board is adopted for final assembly operation. With the increase of project product output and daily supply, preassembly, inspection and online synchronous operation are also used for packaging.

6. Error-proof design of inspection process (error-proof of test system)

The inspection process is to prevent the wiring harness manufacturing error of the next process, including 100% electrical conduction test, pin detection, relay, etc. It is very important to design the process document to prevent error in the testing process.

7. Anti-error design of packaging process

Operations including winding, strapping, bagging and packaging are also a process with fewer quality errors. MES This system executes electronic packaging procedures and uses a code scanner to scan the code on the finished wiring harness one by one. When the number of code scans satisfies the whole box, sound alarm will be issued, and the printer will automatically print the label of the outer box, and then directly seal the label of the outer qualified label, which can effectively avoid packaging errors.

8. Closing Remarks

It is necessary to design error-proof in the manufacturing process of automotive wiring harness. The application of error-proof design can greatly reduce the rework and maintenance caused in the manufacturing process, reduce the manufacturing cost, improve labor efficiency, and ensure the quality of wiring harness effective measures and important means.