In this article, electronics purchasing professionals will discover why wiring automation is as much about supply chain re-engineering as manufacturing efficiency.
In the manufacturing sector, the current geopolitical situation demands a shift towards onshoring and investing in automated manufacturing as strategic priorities. One often overlooked aspect is the production of wire harness assemblies which are invariably produced largely by hand.
The traditional approach to manufacturing wire harnesses relies heavily on manual labour. Initially, wire bundles are pre- assembled into kits using crimping, ultrasonic welding, and twisting. In the final assembly phase, harnesses are built on form boards, with assembly personnel usually mounting wires onto the boards. Each employee must follow complex instructions to ensure quality control throughout the processes.
Aside from posing the risk of errors in the manual assembly process, this labour- intensive phase is usually outsourced to regions with low-cost labour. In an era marked by both diplomatic and trade tensions, this outsourcing model poses risks to supply chain stability.
The answer to the challenges of increasing demand, the need to re-shore production to shorten and strengthen supply chains, and the issue of finding enough people lies in embracing automation technologies. While automation has been challenging due to the complex tasks involved, recent advancements in robotics, artificial intelligence, 3D additive manufacturing and machine vision offer unprecedented opportunities for streamlining production.
Q5D’s approach to wire harness automation employs a 5-axis robotic CNC manufacturing cell with multiple interchangeable tools that lays down conductive wires or tracks, securing them to a wide variety of surfaces and flexible substrates to integrate the wire harness within the products.
Automation also lets wiring design become a more integrated part of the overall design process, enabling further simplification, efficiency and cost reduction. For example, a car dashboard can be built with all the wiring needed for sensors and actuators, entertainment systems, and lighting and displays integrated into the assembly. Components and sub-assemblies can also be designed for automated final assembly.
When both harness manufacture and final assembly are fully automated, there is potential to reduce manual assembly requirements by 80 to 90 percent compared to current manufacturing methods.
Onshoring and automating wire harness assembly offers compelling advantages for supply chain resilience. By reducing reliance on overseas labour markets, businesses can safeguard against disruptions caused by trade disputes, political instability or logistical challenges. Localising manufacturing not only enhances supply chain resilience but also strengthens domestic economies by creating high-skilled jobs and fostering technological innovation at home.
Q5D’s processes and techniques allow for digital manufacturing with minimal or no fixturing. As a result, automating wire harness assembly also enables customisation at scale, crucial for industries like automotive where space and weight constraints demand tailored products. With wiring automation, manufacturers can efficiently produce customised harnesses for each vehicle model, optimising performance while reducing costs associated with excess materials and labour. It enables a faster, more dynamic response to changes in demand too.
While initial investment may seem daunting, long- term benefits far outweigh costs. Beyond cost savings from improved efficiency and reduced scrap, automation future-proofs manufacturing operations against evolving geopolitical dynamics. Companies embracing automation can gain a competitive edge by enhancing agility, responsiveness and sustainability in an increasingly uncertain world.