From requirement confirmation to finished product delivery, 10 steps with strict quality control to ensure every wire harness meets the highest standards
We have comprehensive wire harness customization and processing capabilities, covering the entire process from requirement confirmation to finished product delivery. Below is the standard wire harness processing workflow, with strict quality control standards at each step to ensure product consistency and reliability.
Confirm Requirements, Start with Precision
Before production, the engineering team confirms the specifications based on the customer's drawings and specifications. Any pending items will be communicated with the customer to resolve production questions before finalizing the manufacturing process, ensuring every step is accurate.
Precision Cutting to the Millimeter
Cut the wire (cable) to the required length and coil it. Operators carefully verify the specifications on the production work order before cutting, using calibrated advanced equipment to ensure the processing quality of every wire.
Professional Stripping, Precision Pre-Soldering
Remove the wire jacket (outer sheath) and unnecessary fillers. Use a professional pneumatic wire stripper to strip the jacket, then perform pre-soldering. Adjust the equipment precisely based on each wire specification to ensure zero damage to the core conductor.
Secure Connection, Reliable Transmission
Crimp the terminal to the wire (cable) core conductor. Use a professional terminal crimping machine, with dedicated crimping dies for different terminals. Strictly adjust the machine and check crimping specifications before operation to ensure each terminal connection is firm and reliable.
Fine Assembly, Quality Assurance
Sort the crimped core wires according to the engineering drawing, assemble them into the connector housing, and reinforce the wire harness strength. All processing methods strictly follow the engineering drawing and SOP, using specialized tools to ensure consistency.
Full Traceability, Clear at a Glance
Affix labels containing specifications, ID, serial number, etc., to each customized wire. Labels help assembly personnel quickly find the corresponding interface and facilitate future traceability of production history, enabling full-process digital management.
Self-Inspection & Cross-Check, Multi-Layer Control
After assembly, perform self-inspection during wire harness production based on the production work order drawings and dimensions, ensuring all manufacturing details are confirmed. Every step is recorded, and every link is traceable.
Four-Wire Testing, Zero Defects Outgoing
All completed wire harnesses undergo continuity testing, resistance measurement, wire position measurement, and insulation resistance testing using a four-wire electrical tester. They are released only after confirming normal electrical performance, ensuring every wire harness meets design standards.
Digital Archiving, Traceable Quality
Record and archive images of the finished wire harness. Production engineering data and appearance are digitally archived for easy future reference, modification, or addition. Digital management ensures precise reproduction of wire harnesses with the same specifications.
Safe Protection, On-Time Delivery
Carefully package with cushioning materials to ensure no damage during shipping, and transport as specified. Full tracking from packaging to logistics ensures products are delivered safely and on time to the customer.
From design to mass production, Winna provides one-stop wire harness customization solutions
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