The harness industry represents one of the most important sectors in our country, which plays a crucial role in various sectors such as automotive, aerospace, and electronics, and has seen significant advancements in recent years. And at Murcal one of the most impactful changes has been the implementation of quality improvement initiatives. These initiatives are essential for ensuring the reliability, safety, and efficiency of harnesses, which are critical components in complex systems for our customers.

In recent years, we have made significant strides in improving our harness building process. These enhancements have not only increased our efficiency but also elevated the quality and reliability of our products. 

Here are the key improvements:

1. Improved Design Tools

We have integrated advanced automation tools into our harness design and manufacturing processes. These tools automate tedious tasks such as wire length calculations, splice positions, and taping quantities. This automation has reduced manual errors and significantly cut down the design cycle time. 

Our adoption of modern electrical and electronic (E/E) system design tools has streamlined the creation of bills-of-materials (BOM) and production designs. These tools support digital continuity, ensuring that data flows seamlessly from design to production without the need for duplicated data entry.

We have implemented robust change management tools that maintain data integrity and reduce design errors. These tools ensure that any changes made during the design process are controlled and approved, leading to higher product and process quality

By utilizing automated formboard layout and bill-of-process generation, we have optimized our production designs. This has allowed us to start harness production faster and with fewer errors, improving overall efficiency and product quality.

We have invested in training programs for our team to ensure they are proficient with the new tools and technologies. This has empowered our engineers to leverage these advancements fully, leading to better harness designs and faster production times.

As well, our process improvements also focus on sustainability. By reducing waste and optimizing material usage, we are not only cutting costs but also minimizing our environmental footprint.

2. Implementation of International Standard: IPC/WHMA-A-620E in the Harness Industry

The IPC/WHMA-A-620 standard, developed by the Institute of Printed Circuits (IPC) and the Wire Harness Manufacturers Association (WHMA), is the industry benchmark for the manufacture and acceptance of cable and wire harness assemblies.

Implementing this standard within the harness industry involves several critical steps to ensure compliance and enhance product quality. However at Murcal we are implementing this standard from Engineering Design

A. Understanding the Standard

The first step in implementing IPC-620 is to thoroughly understand its requirements, as part of getting improvement in our products, the standard is considered during Engineering Design.

This standard outlines materials, methods, tests, and acceptability criteria for producing crimped, mechanically secured, and soldered interconnections. It also covers related assembly activities such as lacing and restraining.

B. Training and Certification

Training is a crucial component of IPC-620 implementation. Our Employees are continuously trained to understand and apply the standard’s criteria.

Our Certified IPC trainers educate our operators and quality inspectors in all details defined by the standard, ensuring that everyone involved in the production process is knowledgeable and competent.

C. Process Standardization

Implementing IPC-620 requires standardizing processes to align with the guidelines. This includes establishing clear procedures for design, production, and quality control.

Standardization ensures consistency and helps in maintaining high-quality standards across all products. It also facilitates easier training and onboarding of new employees.

D. Quality Control Systems

Robust quality control systems are essential for IPC-620 compliance.

These systems should include regular inspections and testing to ensure that all products meet the standard’s criteria.

Implementing methodologies such as Six Sigma or Total Quality Management can help in identifying defects early and maintaining high-quality outputs.

E. Supplier Management

Effective supplier management is critical for ensuring that all materials and components used in harness assemblies meet IPC-620 standards.

This involves conducting regular audits, setting clear quality expectations, and maintaining strong relationships with suppliers. Ensuring that suppliers adhere to the same high standards helps in preventing defects and maintaining product consistency.

F. Continuous Improvement

The implementation of IPC-620 is not a one-time effort but an ongoing process. Continuous improvement initiatives should be in place to regularly review and enhance processes.

This includes analyzing feedback from quality control inspections, customer feedback, and industry developments to make necessary adjustments and improvements

3. Implementation of New Technologies for Testing Process.

The harness industry is experiencing a transformative shift with the implementation of new technologies. Automation and robotics are streamlining production processes, reducing human error, and increasing efficiency.

Our tests are defined by international standards, which are considered the most suitables for the harness industry. These tests are the following.

A. Visual Test

The implementation of visual testing (VT) in the harness industry has significantly enhanced the quality assurance process. Visual testing, a fundamental non-destructive testing (NDT) method, involves the direct

observation of harness assemblies to detect surface defects such as cracks, porosity, and improper connections. This method is highly effective due to its simplicity, cost-effectiveness, and ability to provide immediate results. By using tools like magnifying glasses, borescopes, and video scopes, our inspectors can perform detailed examinations, ensuring that harnesses meet stringent quality standards. The real-time feedback from VT allows for quick identification and correction of issues, thereby improving the overall reliability and safety of the harnesses. This proactive approach not only enhances product quality but also reduces the likelihood of costly rework and downtime.

B. Mechanical Test

The implementation of mechanical testing in the harness industry is crucial for ensuring the durability and reliability of wiring harnesses. Mechanical tests evaluate the physical properties of harnesses, including tensile strength, flexibility, abrasion resistance, and connector reliability.

These tests simulate real-world conditions to ensure that harnesses can withstand the stresses they will encounter during their service life. By identifying potential weaknesses and defects early in the production process, mechanical testing helps prevent failures and enhances the overall quality of the final product. This rigorous testing process is essential for meeting industry standards and customer expectations, ultimately contributing to the safety and performance of the systems that rely on these harnesses.

Murcal Inc is continuously investing on high technologies for our testers, which result in a good improvement in our quality in all products manufactured by us.

C. Electrical Test

As a company committed to the quality of our products, we have started with the implementation of new technologies for electrical testing. After an exhaustive research process by our engineering department, our company made the decision to use Cirris Testers in harness testing, which has brought significant improvements in accuracy, efficiency, and reliability. Here are the key aspects of this implementation:

1. Enhanced Testing Accuracy

Cirris Testers are designed to perform comprehensive tests on harness assemblies, including continuity, insulation resistance, and high-voltage testing. These testers can detect even the smallest defects, ensuring that each harness meets stringent quality standards. The use of multiple simultaneous test measurements allows for thorough verification of all connections and components.

2. Automation and Efficiency

One of the standout features of Cirris Testers is their ability to automate the testing process. By using automated test setups and software-guided assembly, these testers significantly reduce the time required for testing. This automation not only speeds up the process but also minimizes human error, leading to more consistent and reliable results.

3. User-Friendly Interface

Cirris Testers come with intuitive software that guides operators through the testing process. The software provides clear instructions and visual aids, making it easy for technicians to set up and execute tests.

This user-friendly interface ensures that even complex harness assemblies can be tested efficiently and accurately.

4. Real-Time Feedback and Diagnostics

During the testing process, Cirris Testers provide real-time feedback through audible alerts and on-screen graphics. This immediate feedback helps technicians quickly identify and correct any issues, ensuring that only defect-free harnesses proceed to the next stage of production. The ability to diagnose problems on the spot enhances overall productivity and quality control.

5. Flexibility and Customization

Cirris Testers are highly adaptable and can be customized to meet specific testing requirements. Whether it’s a simple low-voltage test or a complex high-voltage test, these testers can be configured to handle various types of harness assemblies. This flexibility makes them suitable for a wide range of applications in different industries.

6. Data Management and Traceability

The software used with Cirris Testers allows for detailed data logging and reporting. Test results can be stored, analyzed, and traced back to specific harness assemblies, providing valuable insights into the production process. This data management capability is crucial for maintaining quality standards and ensuring compliance with industry regulations.

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For Technical Support, Please Call Us At 661-272-4700, Contact Us Or Email Us At Sales@Murcal.Com

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