Automotive Wiring Harness: Veneer Assembly Process Analysis

Veneer assembly production refers to one or more people in a fixed area of a tooling board, according to the process documents will be wire, sheath, fuse, tie and other materials assembled into a qualified finished wiring harness. It is commonly used in some wire harnesses with a small number of wires. Such as: four-door harness, air conditioning harness, positive and negative harness, etc. The design of the wiring harness veneer assembly process is mainly divided into the following steps.

Calculate the standard operating time

Calculate the standard operating time for single harness assembly, and determine the number of veneer tooling stations according to the planned daily production volume.

1. The standard operating time is relative to the internal enterprise, which is a measure of production efficiency set by the enterprise. The standard operating time will be different for different enterprises due to differences in software and hardware, Table 1 shows the standard operating time of a wiring harness of an enterprise.

2. After the standard operating time of a single wire harness is calculated, the daily production can be calculated according to the customer's demand plan to determine the number of workstations. If a wire harness customer plan demand is 5000 sets/month, the enterprise monthly working days for 24 days, working 8 hours a day, each single harness standard operating time of 0.3 hours, then the number of workbenches can be in accordance with the following formula: the number of workbenches = (customer monthly demand × standard operating time) / (daily working time x the number of working days per month)

3. From the above formula, we can see that the number of workstations demanded is inversely proportional to the working time of assembling this harness. In the case of fixed monthly customer demand, the longer the working time of this workstation is arranged, the less the number of workstations will be. When the working time is 12 hours a day, or when two shifts are adopted (16 hours a day), or when three shifts are adopted (24 hours a day), the corresponding number of workstations demanded will be reduced, thus achieving the effect of reducing the site area, but at the same time increasing the corresponding number of operators.

Production of reasonable tooling racks and wiring boards

1. The storage of materials harness materials generally refers to the sheathing, wires, ties, tapes, external protection tubes and other materials, this material should have a fixed storage location, the placement of materials should not be too high, nor too low, in order to facilitate access to the operator, to prevent errors as the principle.

2. Waste storage harness waste is divided into two categories: recyclable and non-recyclable, recyclable waste includes tape rings and tie heads, etc.; non-recyclable waste includes plastic bags and broken tape heads, etc.

The wiring board generally has a fixed wiring board for each wire harness. The wiring board is placed on the tooling rack and made in the ratio of 1:1 according to the drawing size; the wiring board must contain the operation information identified by the operator, such as: wrapping method, wrapping length, material type, wire number, tie type, etc. The trunk branching direction takes the form of straight lines, avoiding bends in the wrap.

Process documentation

The process document generally contains the operation content, specification requirements. The operator assembles the wiring harness step by step according to the guidance of the process document; when more than one person operates on a wiring board at the same time, each person's division of labor should be clear, and the operation should not interfere with each other and have a clear sequence of operation.

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