Automotive wire harness welding Some problems in automotive wire harness processing and disposal plan

 Cutting process

Poor line cutting results:

1, peeling size is poor: lead to the next process (crimping) can not operate normally, also lead to unqualified waste.

2, the wire size is poor: the wire size is too short, resulting in unqualified waste line.

3, core damage, oxidation: poor crimping, virtual connection.

Defective product disposal process: (bad size as an example)

1. Operator: If the size is too short, immediately find out the cause of nonconformity, communicate with the inspector to deal with it, avoid presenting batch defective products, and directly scrap the short size, and shall not be mixed with qualified products to the next process; Rework with wire strippers for long dimensions to be confirmed by inspectors.

2. Inspectors: sampling found defective products, begged to immediately find the reason and rectification, and the defective product review and disposal, assuming that the batch of defective products, should immediately stop rectification, and report directly under the guidance.

Crimping operation

Results of poor crimping:

1. The pulling force is too small: the core and the end are virtual or scattered.

2, ordinary poor crimping will lead to a lot of waste, and rework is difficult, easy to scrap.

Defective product disposal process: (pulling force is too small)

1. Operator: the tension is too small should immediately stop the crimping, and contact the mechanic to stop the crimping mold and report to the inspector.

2. Inspector: the same type of crimped terminals (one test passed to found defective), all according to 2% spot inspection test, the test found defective products are judged to be unqualified, do a good job of identification and isolation, and notify repair.

Assembly process

Results of poor assembly:

1, terminal exit: assuming that the plug terminal is not implemented according to the specification, the terminal exit is not easy to be found will be directly sent to the customer, the terminal plug is not in place will constitute a virtual connection, resulting in burning.

2, terminal dislocation: ① The wiring harness of the wrong terminal insertion hole is assumed to be intercepted on the test bench, which will lead to double rework of the pre-installed staff and the tester, seriously affecting the consumption efficiency. ② Assuming that in the test area mixed or leakage test, the wrong terminal insertion hole will directly cause the short circuit of the car line. \

Defective product disposal process: (terminal insertion wrong hole)

1. Operator: ① If the terminal is inserted incorrectly, it should be picked out immediately with the appropriate tool and reinserted into the sheath according to the process specification. Try not to damage the parts during operation. ② All the same type of sheath all self-test.

2. Inspector: After the end of self-inspection, the inspector will fully check and confirm the type of sheath, assuming that the defects are found again, the punishment regulations will be implemented.

Line winding process

Bad result of pipeline:

1, harness size is poor - resulting in no loading.

2, the branch direction is not correct - the size is short when loading.

3, the second distribution terminal insertion error - repair or burn the car.

Defective product disposal process: (branch direction is incorrect)

1. Operator: In the case of self-inspection or the inspector tells the branch direction is not correct, immediately improve, wrap according to the correct branch direction, and identify, isolate, centralize and rework the unqualified product.

2. Inspector: If defective products are found in the inspection project, mark and isolate the defective products, immediately notify the workshop supervisor, explain the defective reasons, and assist the workshop in rectification. Assuming that there is a batch (30) quality problem, the full-time inspector has the right to stop the line, find out the reason, and report to the immediate supervisor.

Conduction test procedure

Beg:

1. Mark and isolate the wiring harness that fails the test (place it on the rework wire rack according to the model and cause of failure);

2, shall not put different types of wiring harness on the same line frame;

3, shall not hang the defective products on the line rack of qualified products;

4, the qualified products in the specified period of packaging;

5, do not use violence.