These processes include but are not limited to the following:
• Installing the wires and/or subassemblies on the assembly board.
• Routing wires and/or subassemblies through any required sleeves.
• Applying wraps, ties, or tapes, particularly on any branch-outs.
• Crimping terminals onto wires, especially if more than one wire goes into one terminal.
It is difficult to automate the processes used in the building of a wire harness. Manual production remains more cost-effective than automation, especially with small batch sizes. Pre-production or kitting of a harness can be somewhat automated.
This would impact the following steps:
• Cutting and identifying individual wires (cutting/stripping machine).
• Crimping terminals onto one or both sides of the wire.
• Partial plugging of wires fitted with terminals into connector housings.
• Soldering of wire ends (solder machine).
• Twisting wires.