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Abstract In the scope of this study, pre-assembly operation in the wiring harness manufacturing factory is
improved. By using digital technology during pre-assembly operation, possible operator mistakes and quality
problems due to confusion of hardcopy documents are prevented and correct part production is provided. Uploading
pre-assembly operation sheets into the system is enabling operators to reach the required documents quickly as well
as reducing manpower time loss caused by printing and distribution of hardcopy documents. As a result of this
application, 74% time saving and annual 254.524 number A4 size paper and indirectly tree saving are provided. In
addition to saving, operator mistakes are 47, 77% improved. In other words, Company related expenses are decreased
from 10220$/year to 442, 5$/year.
Two interfaces are designed for software. The first interface is used by designer for uploading more than 3000 type of
designed pre-assembly operation sheets to system. Second interface is used by operator for displaying the required
pre-assembly operation sheets from the system. In order to provide ergonomic use of the devices by the operators, 3
axis movable tpe of telescopic hangers are installed.
Keywords: Wiring Harness, Production, Software, Environment, Saving, Mistake
I.
INTRODUCTION
Wiring harness is one of the most important parts in the
vehicle after engine and transmission. Wiring harness, like
nerves of a human being, has main role in the transfer of
electrical signals, operation of the functional and safety parts.
Although wiring harness cannot be seen easily out of engine
room, they are one of the most critical parts as they are
assembled in the beginning stage of vehicle assembly and
enable the operation of all vehicle functions. Due to earlier
assembly of wiring harness, repair may require disassembly of
many parts assembled on it when there is a quality problem.
After vehicle, wiring harness is the first coming part that is
subject to biggest BOM including different type of sub parts,
many engineering modifications in parallel to improvements
and manpower requirement during production. Considering
significance and manpower requirement in the production
process, any studies decreasing quality problems and cycle
time is having significant and key role in the competitive
market in the aspect of cost, safety and comfort. [1]
All wiring harness type has independent assembly
production line and a production loop inside the line [2]. Each
conveyor line is working like a loop system on which
assembly tables are located as a working station of the
operators and wiring harness assembly production is
completed when a loop is completed [3]. Conveyor is moving
production line and carries between 22 and 25 wiring
assembly tables. There are pre-assembly working stations in
parallel to one side of conveyor. The operators should check
all pre-assembly operation sheets before each production [4].
These documents are including socket scheme and wire
assembly position on the connectors. Sample connector
scheme is given in figure 4.1.
PROGRAM / SOFTWARE
Using the method of application program interface is
designed according to the industry common workflow with
Visual Basic [6] interface program considering work flow.
This interface program is including name of production line,
part number and number of pre-assembly operation sheet
(Figure 3.1). Operators can easily reach and display required
sheets by using designed program. However, operators dont
have any permission to reach other line sheets or to change
information on the sheets.
II.
DEVCE & EQUPMENTS
In accordance with operation flow, almost has a great
computer features and ease of use of space-saving mini
computers [5], 18,5 inch LCD screen and mouse is preferred
considering easier and modular use.
III.
REQUIRED D OCUMENT
CONCLUSION
VII.
REFERENCES