Wiring Harness News WHN Sept-Oct 2020 WHN Sep-Oct 2020 - Page 25

INDUSTRIAL INFO-TAINMENT Wiring Harness News SEPTEMBER/OCTOBER 2020 25 Improving Outcomes for Our Clients in Electronic Harness/Interconnect Manufacturing Continued from page 23 ____________ 2. Sizing of consumables such as sleeving to the bundle size. In fact, many software products tools don’t effectively predict the bundle sizes thus the definition of important consumables such as braiding, sleeving or boots is arbitrary (with a high potential for error) and often forcing the correct choice to be made as part of the production process 3. Existence and location of splices in the harness and their impact on the bundle size 4. Is the correct material properly defined and cataloged or are there mistakes in the parts-lists? 5. Does the schematic match the BOM or are there key omissions? 6. Are the parts called out meeting the application for environmental requirements such as ROHS, temperature, voltage? 7. Is the BOM accurate (correct quantity of contacts, solder devices identified, right length of wires and consumables, etc.)? As a Result, “Trial-and-Error”, On-The-Fly Changes More the Rule than Exception At El-Com Systems we have spent countless hours supporting the design output of many of our customers. Given the volume of incoming requirements, and the experience required of our engineers to properly evaluate the design and estimate scheduling and costing of new requirements, we have always found it very challenging to identify (discover) many customer mistakes until we reach product realization phase, when the impact is already too great. El-Com has polled many peers and customers and it seems to be a common theme in this field that we accept a “trial-and-error” approach to building harnesses at an NPI level and we accept some sort of “on-thefly” changes when we find mistakes, which is quite often and as previously stated can be quite costly and negatively impactful (cost and schedule). El-Com Teaming with Key Players to Provide Design Validation Given that El-Com has seen the negative impact of design errors, not just on our customer performance, but on our own operational execution as well, we have decided to invest our time and resources to provide OEMs with a more comprehensive design validation output. We have teamed with key customers, industry peers, and technical experts to improve our approach for design val- _____________ Continued on page 27