How To Survive The Wiring Harness Factory

The new crown epidemic has caused a great impact on the global manufacturing industry, so how to survive for wire harness manufacturers is an urgent issue. Today, the wire harness factory will talk about how we deal with the current dilemma?

　　 1. Improve the quality of wiring harness products

　　 The quality of products requires good raw materials and processing equipment, as well as the concerted efforts of employees. The departments must cooperate closely, the quality control department strictly controls the quality, and the technical department timely adjusts the process when product problems are found. As we continue to solve some small problems in the process of wire harness processing, we have gradually formed our own advantages, and details determine success or failure.

　　2, improve production efficiency

　　Improving production efficiency while strictly controlling quality is something that every company should consider. In assembly line operation, the balance between workstations is very important. As long as there is a problem in any link, the product cannot be improved. Managers need to find the problem in the production and processing process, and then rationally arrange the workstations to increase production capacity.

In the automotive wiring harness industry, there are two production modes, the first is the tooling board assembly line, which is suitable for large wiring harnesses in the engine compartment and the inner cabin, and the second is the veneer production, which is suitable for various door lines/sunroofs/bumpers and other small lines; Either way, the pursuit of efficiency is necessary. Take out traditional IE analysis and observation techniques and tools, carefully observe the subdivided actions in the whole process, and define which actions are not value-added and need to be eliminated, and which actions are necessary but can be used Fixtures or other tools assist employees to speed up, objective statistical analysis will come up with plans for improvement.

　　3, Optimize the layout

　　Optimizing the layout includes the overall layout of the factory and the layout of the workstations

　　Considering the separation of different areas, testing, final assembly, pre-assembly, and blanking are arranged in the order of production. After the overall layout is determined, the processing area and material transportation routes for workers must also be determined. Try to be straight, avoid detours, and save materials and personnel time.

　　The layout of the workstations makes it convenient for employees to take materials and is not easy to make mistakes. Tooling boards/material tables/wire racks are the three types of materials placed in the wire harness factory; in many cases, tooling boards have become the first choice for lightweight materials, such as staples/cables/tapes and other small materials, because employees face the tooling board Take it directly without turning around.

　　 Larger materials, such as connectors/protective sleeves/plastic parts that need to be assembled, are generally placed on the material table behind the employees, and they can be picked up by turning around without walking. The above is the material placement in the assembly area. The materials and wires in the pre-installation area are generally placed on dedicated wire racks, and each type of different wires can be identified by a label location.

　　 Improve space utilization. Especially the workshops are rented, and more attention should be paid to the space utilization rate. Currently, there is no fixed mode of thinking. It needs to be dealt with according to the actual situation in the work. It saves space while taking into account the convenience of employees. Wire racks like the above are more successful cases.

　　4. Control the scrap rate and reduce employee fatigue. In the process of station operation, employees have many unreasonable actions that do not add value. We need to find out one by one to eliminate. There is a set of scoring standards. According to the definition, the current position is scored. The lower the score, the more improvement is needed, which is more scientific and reasonable.

　　 The material is too far away from the employees and needs to move around. This is unreasonable and needs to be improved. There is also the positioning of workstations so that employees can only move around within a limited range to avoid wasting physical strength and time. Many problems require us to continuously explore and improve in our work to reduce waste and unnecessary fatigue caused by unreasonable operations. Once employees are tired, the quality and efficiency will inevitably decrease.

　　5, production logistics kanban system

　　 With the popularization of lean production concepts, kanban systems are increasingly used in most factories. Kanban is the back end pulls the front end, and the demand side pulls the supply side. Therefore, the production quantity is basically accurate, and the quantity determines the output.

　　 There are many people at the production site, and the information transmission is not timely due to the different division of labor. After the Kanban management is implemented, anyone can learn the production information on the spot in time from the Kanban, and master their own work tasks from the Kanban, avoiding omissions in information transmission.

　　6, wire optimization

　　In a finished wiring harness, fewer wires means lighter weight and lower cost, but this must be done under the premise of ensuring product quality. In the early sample stage of the project, a comprehensive statistics should be made on all wire lengths of the wiring harness to see which wires are too long or too short to be optimized. This requires accurate simulation and evaluation. Optimization is made in the sampling stage, which is worth noting. , The wire, especially the welding wire, would rather be long than short, because if it is long, it can be optimized later.