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Coaching children’s recreational league basketball when my kids were growing up was
very rewarding—even if it was more like herding cats than playing actual basketball. There
is one thing that stands out in my mind, however, and that was when a play worked the way
we designed it. We first diagramed the play out for the kids, and then we practiced it
until they understood the moves. When it finally came together in a game, it was a
beautiful thing to see.
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Today, as I work with <a href="https://www.fpwires.com/" target="_self">wire
harnesses</a> that are built for electronic devices, I am reminded of those days coaching
the kids on how to put the play together. First, the wire harness specifications are drawn
up in the same way we would diagram the play. Then, the harness is meticulously laid out,
just as we demonstrated to the kids how to execute the play. There’s a lot more to the
process of course, and thankfully, the wire harnesses usually don’t talk back to us. Here
are more details of the <a href="http://www.fpwires.com/pcb-wiring-harness/"
target="_self">PCB wiring harness</a> manufacturing process that your contract manufacturer
should go through when building your assemblies.
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Input: What Your CM Needs for the Wire Harness Manufacturing Process
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Contract manufacturers often build both <a href="http://www.fpwires.com/flat-ribbon-
cable/" target="_self">flat ribbon cable</a> assemblies and wire harnesses. To
distinguish between the two, a <a href="http://www.fpwires.com/multicore-cable/"
target="_self">multicore cable</a> assembly is an external connection to devices and will
have different environmental considerations, such as their thickness, insulation type, and
flexibility. A wire harness, on the other hand, will provide the connectivity between
systems in an electromechanical assembly, such as connecting a power supply to a
motherboard.
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Wire harnesses are laid out and built on a panel that has pegs positioned strategically
where the wires will branch out into different directions, or connectors need to be added.
This way, the harness is laid out to the exact dimensions that are required. Usually, you
specify these dimensions, and contract manufacturers are used to getting a wide range of
information to work with. The information can be something as simple as a hand-drawn note,
or a series of complex 3D CAD models, as well as everything in between.
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However, as with anything that is manufactured, the more detailed documentation and
precise specifications you can provide, the fewer problems there will be on the assembly
floor. Here is a sampling of the data that will best help your contract manufacturer when
building your wire harness:
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Detailed connectors images that show pin locations.
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Wire lists that specify wire colors, nets, and connector pin-outs.
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Bill of materials with part numbers.
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Full assembly drawing with label locations, assembly instructions and tolerances.
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Finished harness test specifications.
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Key Points of the Manufacturing Process to Build Your Wire Harness
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With the documentation in hand, you should expect your contract manufacturer to follow
a general process in building your wire <a href="http://www.fpwires.com/cable-harness-
assembly/" target="_self">cable harness assembly</a>:
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