Rework of wire harness

In the production process of wire bundle products, quality exists in all aspects. Therefore, we must ensure that the quality of the finished product is fully inspected to ensure that the shipped goods meet customer requirements and customer satisfaction. However, during this period, non-conforming products will not be avoided in the production process of the wire harness seal, and internal rework is required to re-achieve the products that meet the requirements.

For the assembly assembly, the most common ones are the misalignment of the wiring harness, the damage or poorness of the connector, the bare copper wire of the wire, the misalignment and misalignment of the wire tie, the poor rubberization, and the poor crimping. Select a few for detailed analysis below:

(1) Misplacement.

There are many types of terminals and different shapes. Even if the connectors of the same type are different, it will lead to the development of different rework tools. After the rework, the terminal spurs are not damaged, and when the connector is inserted, a "squeak" sound is heard as good rework. However, in the online beam rework, the gold-plated terminal seals are prohibited from rework, and the safety parts such as antennas, USB, and shielded wires are also prohibited from rework.

(2) The connector is damaged or defective.

There are three types of connectors: no lock, self-locking, and secondary locking. If there are individual defects in the production process, the red label should be placed in the defective magenta box and scrapped. If it is a batch problem, it should be returned to the supplier for screening. First, select a good batch from the warehouse to give priority to use. The reworked connector should have no visible scratches and the lock can be locked normally. Note that the safety parts such as the airbag case cannot be reworked.

(3) The line is misused or misplaced.

The wire tie is fixed at both ends and the tail is tightened. The presence or absence of test leads and the use of faults can be used for electrical testing or OGC. OGC modules and test modules can be used for error proofing. When reworking the line, pay attention to not scratching the wire and rubber. When re-fixing the wire, the rubber can not cover the functional area, and the tail of the application should be tightened with the corresponding wire gun. Generally, the OGC module can guarantee the positioning. If the wire tie test is used, the full check is used for comparison, and the special slide package is available.

(4) The dimensions do not conform to the drawings.

Silicone wire harness seals are different on the tooling plate, and there is a slight deviation in size. Once the tolerance is exceeded, rework is required. Small branches can be reworked directly online. Once the trunk branch is encountered, most of the glue and wire tie may be required. Therefore, the full inspection is also the last barrier to close the harness.

All rework separation lines and online, regardless of the type, should be reworked by qualified and professionally trained personnel. The rework tools used should be placed in the toolbox and marked accordingly. Rework tools are inspected regularly, even if repairs are replaced. For each reworked wire harness, the rework operation record should be made, including date, production area number, defect cause, quantity, reworker signature, etc., in order to carry out traceability and defect statistics later. For recurring rework reasons, there should be corresponding corrective actions and FMEA/CP/PPM analysis to avoid or reduce such rework.

Rework is just a remedy after a problem. What we need to do is to improve daily and optimize to ensure that good quality is made, not by inspection. To improve customer satisfaction, increase market share; reduce defects, reduce risks and costs; improve products and services as the ultimate goal, thereby accelerating improvement and making the organization sustainable.