A guided harness assembly and test system makes sure that assemblers insert wires correctly by giving them instant feedback. If wiring errors can be detected when and where they occur, preferably by the assemblers, then quality goes up while overall cost is driven down.

Recent price fluctuations have forced some manufacturers to consider alternatives to copper wire, such as copper-clad aluminum, solid-core aluminum and composite wire.

Presses for terminating wires have benefited dramatically from advancements in electronic control technology.

Whether joining two wires together or attaching multiple wires directly to a terminal or assembly, engineers must choose between resistance welding, soldering and ultrasonic welding.

Wire harnesses are used in everything from sports cars to washing machines and business jets to video arcade games. But, assembling them can be a daunting task. Choosing the right wire harness boards and fixtures can improve productivity.

Demands for higher quality and higher production volume have led to many innovations in wire termination.

Lean manufacturing concepts helped Arrow Electronics improve its assembly processes. But, progress was often short-lived. Read how this cable and wire harness assembler took lean manufacturing to the next level.

Forming a satisfactory crimp depends on the right combination of wire, terminal and tool.