How quality assurance can also be achieved using manual processes

Gilching, September 26, 2024 – Wiring harnesses are becoming more and more safety-critical. This presents huge challenges for MES systems from wiring harness producers because they must guarantee continuous quality assurance. DiIT explains how this can be achieved despite the many manual work processes.

Electrification, connected car and autonomous driving are making vehicle wiring harnesses more and more safety-critical. This means therefore their quality requirements have also increased. Manufacturing Execution Systems (MES) from wiring harness producers play a decisive role in meeting these requirements. Their task is to control and document the production of wiring harnesses below the ERP level which in turn also makes them the central IT system for quality assurance.

The many semi-manual and manual processes still used in wiring harness production are a major challenge for MES. Although wire cutting is highly-automated, wiring harnesses are then mostly pre-assembled manually and their final assembly is even performed completely by hand. Automated quality assurance and traceability across all three production steps is therefore impossible.

DiIT, a specialist for integrated software systems in wiring harness production, explains how an MES can still support wiring harness producers to continuously meet the increasing quality requirements:

1. Cutting. It goes without saying that the CST (Cut, Strip & Terminate) machines used for cutting and bundling wires ensure high precision from the outset. An MES can also help improve quality assurance by transferring control data such as crimp data directly to the connected machines. It can also enforce quality-assurance measures, for instance by scanning and monitoring tool maintenance cycles. The MES also assigns a unique ID to each wire bundle which forms the basis for continuous traceability.
2. Pre-assembly. In the second production step the wire bundles pre-produced in the cutting area are assembled through crimping, welding and twisting into simple kits. During the production of each kit the MES can generate a new ID and store all the components that go into the kit so that its history is complete. The MES can also directly instruct employees at their semi-manual workplaces. As regards product quality this reduces the high risk that can arise with the lack of qualifications in new and inexperienced employees.
3. Final assembly. In the last production step the wiring harnesses are assembled on so-called assembly boards. An MES can control this complicated process by using on-site monitors to display in detail the relevant work steps to the employees. Employees can also be prompted by the system to confirm certain steps, perform test steps or input QA relevant data. If the system also updates the history in the final assembly, it can be easily determined subsequently which vehicles have wire harnesses incorporated with wires from a specific batch. This also can enable any repairs or recalls to be isolated.

“Software-controlled quality control is now essential for wiring harnesses in increasingly digitized vehicle technology. Otherwise, the necessary quality cannot be guaranteed explains Bernd Jost, Managing Director of DiIT. “As wiring harness production involves many specific aspects, generic MES systems are not suitable for this purpose. In-house developments are also associated with high costs for setup and maintenance. This is why the best solution for wiring harness producers is to use the relevant custom solutions.”

DiIT GmbH, based in Gilching near Munich, is the world’s leading provider of integrated software solutions for manufacturing execution (MES), customized wire harness production and logistics. DiIT‘s competencies are bundled in the “4Wire Solutions” software suite, which is primarily used for the production of wire harnesses and wiring systems in the automotive industry and other industrial sectors. By digitalizing the value chains, the company‘s innovative software optimizes and controls complex manufacturing and logistics processes and supports quality assurance and traceability. DiIT was founded in 1990 and has a subsidiary in Berlin. DiIT is also represented in the key markets Mexico and China. The company offers a comprehensive services package to both large and small customers which covers consulting, project management and customized implementation and training. The DiIT support line is available during 24 hours and 365 days. Part of the Komax Group, DiIT operates as an autonomous company. Komax is a global technology group and a leading supplier in the wire processing industry.

More information:
Patricia Lange
DiIT GmbH
Ferdinand-Porsche-Str. 3
D-82205 Gilching
Tel.: +49 89 8932500
info@diit.de