Research on Application of Error Proofing Technology in Design and Manufacture of Automobile Harness

Error-proof technology refers to any device or facility that can prevent the occurrence of human errors, or make people find errors at a glance. Antibugging, also known as the method of foolishness, means to prevent mistakes before they happen. With the rapid development of automobile technology, the number of vehicle-mounted functional appliances has doubled, which leads to the increasing size of automotive wiring harness connecting various functional appliances. Especially in automotive wiring harness with integrated design, the manufacturability of wiring harness is seriously reduced due to the large number of wiring harness loops, huge volume and heavy weight of wiring harness. Therefore, the error-proof design of automotive wiring harness products and process manufacturing is particularly important. Combined with the relevant materials in product design and manufacturing process design of domestic automotive wiring harness industry, the application of error-proof technology is summarized, and we can exchange and learn with colleagues.

Whether it is the semi-finished wire harness inspection or the off-line inspection and detection of the finished wire harness, it belongs to the end inspection after processing. The detection means are relatively limited and the detection rate is relatively low. To improve the detection rate, it is often necessary to invest more in the detection equipment, but the detection efficiency sometimes cannot meet the requirements of the production beat. After detecting the quality problem of the harness, the site, personnel and materials need to be put into repair. In the process of repair, secondary damage may be caused. The quality defects of automotive wiring harness, such as missing-loading, are often controlled based on the strategy of blocking the quality risk points afterwards through the quality control in the production process and the end inspection. The invested resources are too large to guarantee that the quality defects can be completely avoided. If some potential quality hazards that may occur during the production and assembly of the main engine factory are taken into account in the wire harness design stage, the error-proof technology should be applied in the product design stage and production process to avoid the quality hazards of the wire harness in advance, and a small amount of resources should be invested to advance the time point of quality control, and the effect will be relatively obvious. At the same time, the manufacturing cost of the wire harness can be greatly reduced, the production efficiency of the wire harness can be improved and the quality can be guaranteed.

With the rapid development of automobile technology, the number of electronic and electrical components and functional components in automobiles is increasing, and the wiring harness connecting each electrical component is becoming more and more complex, and the number and volume of loops of the wiring harness are also increasing rapidly. As a result, the process design, manufacturing, process inspection and quality control of the wiring harness bring great difficulties, which inevitably leads to various artificial manufacturing errors in each process of wiring harness manufacturing, resulting in batch repair and rework of semi-finished wiring harnesses or finished wiring harnesses, which seriously affects the manufacturing efficiency and products of wiring harnesses. Then using error-proof technology in the process of wire harness manufacturing, through the process error-proof design and tooling error-proof design, becomes an effective means to avoid the occurrence of wire harness manufacturing errors. This paper summarizes the relevant experience in the wire harness industry, from the wire harness product design to the wire harness manufacturing process, and expounds the application of error prevention methods in practical work, so as to learn and discuss with colleagues.

Error-proof technology refers to any device or facility that can prevent the occurrence of human errors, or make people find errors at a glance. According to the effect of error prevention, error prevention technology can be divided into the following three levels: ① Error prevention without manufacturing defects, that is, it is impossible to manufacture bad parts, and the number of possible damaged parts is zero; (2) Failing to pass the error prevention of defects, that is, it is impossible to pass the bad parts to the next station; (3) Do not accept the error prevention of defects, that is, the subsequent stations will not accept bad parts.

The characteristics of error-proof technology: First, it can find potential problems. Error-proof technology itself has strong preventionability, and one of its significance is that it can find potential problems in time, so that producers can have enough time to deal with errors and prevent economic losses caused by erroneous production. It can be said that one of the main logics of error-proof technology creation is to find problems, analyze them, solve them, and summarize and analyze them. Second, eliminate the influencing factors of product defects. Error prevention technology can prevent the wrong production of products and reduce the corresponding economic losses. But if we want to fundamentally avoid the occurrence of errors, we should fundamentally eliminate the causes of errors. The application of error-proof technology can just discover the causes of errors from the source, deal with these unfavorable factors in the most reasonable and appropriate way, and eliminate the influencing factors of product defects.

No matter in the process of product design or manufacture in automotive wiring harness, it is best to start from the source to solve the problem fundamentally, so that the error-proof position can be identified. Especially for the automotive wiring harness project developed by the whole service, at the initial stage of the design of the wire harness products, we must make full use of the structure error prevention, component error prevention, color error prevention, size error prevention, docking error prevention and other comprehensive error prevention technologies to ensure the manufacturing and loading error prevention in automotive wiring harness, so as to realize the error-free blind loading of automotive wiring harness in the main engine factory and correct loading, and to realize the correct identification of products in the manufacturing process of automotive wiring harness and the correct interpretation of drawings.