The service process for customized product orders needs to take into account both the flexibility of customization and the standardization of industrial mass production. The specific process and key points are as follows:
I. Demand docking and evaluation stage
The core of this stage is to clarify the details of customer customization needs, evaluate the factory's technical capabilities and feasibility, and lay the foundation for subsequent processes.
1. Customer demand information collection
- Basic information confirmation: Obtain the application scenarios of customer customized wiring harnesses (such as automobiles, industrial equipment, communication base stations, etc.), functional requirements (transmission signal type, voltage/current level, transmission rate, etc.), and environmental requirements (temperature range, oil resistance/temperature resistance/vibration resistance level, protection level IPXX, etc.).
- Technical parameter docking: Collect detailed technical indicators, including:
- Wiring harness structure (single core/multi-core, whether with shielding layer, number of branches and length).
- Connector type (such as FAKRA, J1939, IX industrial interface, etc.), pin definition, and plug-in and pull-out times.
- Material requirements (conductor material such as oxygen-free copper/silver-plated copper, insulation layer material such as PVC/silicone/PTFE, shielding layer type such as braided mesh/aluminum foil).
- Industry standards (such as automotive grade must comply with ISO/TS 16949, SAE J1939, industrial grade must comply with IEC 61076, etc.).
2. Technology and feasibility evaluation
- Technical feasibility analysis: The engineering team evaluates whether the customization requirements are met based on the needs and the factory equipment capabilities (such as terminal crimping accuracy, shielding layer processing technology, and automated branching equipment) (such as high-frequency transmission requires special shielding design, and extreme environments require temperature-resistant materials).
- Cost and cycle calculation: Based on material selection (such as gold-plated terminals vs. tin-plated terminals), process complexity (such as multi-branch Y-type structure, high-precision shielding layer welding), and production batch, calculate the cost (material + processing fee) and delivery cycle (including design, proofing, and mass production time).
- Risk prediction: Through preliminary DFMEA (design failure mode and effect analysis), identify potential risks (such as signal interference, insufficient mechanical strength), and propose avoidance solutions (such as adding shielding layer, optimizing terminal crimping parameters).
II. Solution design and confirmation stage
Based on customer needs and evaluation results, output customized technical solutions to ensure that both parties reach a consensus on product standards.
1. Detailed solution design
- Structural design: Use CAD (such as AutoCAD, SolidWorks) to draw a 3D model of the wire harness, clarify the wire specifications (AWG wire diameter), connector model, branch point location, shielding layer wrapping range, fixtures (such as brackets, cable ties) layout, etc.
- Process design: Develop a production process (such as wire cutting → terminal crimping → shielding layer processing → branching welding → connector assembly → testing), and mark key process parameters (such as terminal crimping height ±0.01mm, shielding layer coverage ≥90%).
- Standard compliance verification: Ensure that the solution meets the industry standards specified by the customer (such as automotive wiring harnesses must pass the SAE J2288 vibration resistance test, and industrial wiring harnesses must meet the IEC 60512 plug-in life requirements).
2. Customer confirmation and agreement signing
- Submit a technical proposal to the customer (including drawings, bill of materials BOM, process description, test standards), and conduct technical briefings to answer customer questions (such as the impact of shielding layer design on signal anti-interference, and the balance between material selection and cost).
- Confirm order details: batch quantity, delivery cycle, acceptance criteria (such as AQL sampling level), price and payment method, and sign a formal contract and technical agreement.
III. Sample trial production and verification stage
Verify the feasibility of the solution through small-batch trial production to ensure that the product meets the requirements before mass production.
1. Sample production
- Start small batch trial production (usually 1-5 sets of samples) according to the design plan, use equipment and processes consistent with mass production (such as automatic terminal crimping machine, laser wire stripping machine), and focus on monitoring key processes (such as Y-type branch point welding strength, connector assembly sealing).
- Sample identification is clear (including material number, production date, test status), and a sample report is attached (recording production parameters and material batch information).
2. Full test and verification
- Electrical performance test: Use network analyzer, voltage tester and other equipment to detect conductivity (on-resistance ≤ 5mΩ), insulation resistance (≥ 100MΩ), withstand voltage (such as AC 1500V/1min without breakdown), signal transmission rate (such as CAT7 needs to support 10Gbps).
- Mechanical performance test: tensile test (terminal pull-out force ≥ 50N), vibration test (such as 10-2000Hz random vibration, amplitude ±2mm), plug-in life test (contact resistance change ≤20% after ≥5000 plug-ins).
- Environmental adaptability test: high and low temperature cycle (-40℃~125℃, 100 cycles), salt spray test (5% NaCl solution, no corrosion for 96 hours), oil resistance test (no performance degradation after immersion in diesel/engine oil for 72 hours).
3. Customer confirmation and solution iteration
- Submit samples and test reports to customers to assist customers in installation verification (such as testing signal stability and installation adaptability on customer equipment).
- If the customer proposes modification suggestions (such as adjusting the branch length, changing the connector brand), return to the design stage to optimize the solution and repeat the trial production process until the sample passes the customer's first article approval (FAI).
IV. Batch production and process control stage
After the sample is confirmed, mass production is started, and product consistency and quality stability are guaranteed through standardized processes.
1. Pre-production preparation
- Material procurement and inspection: Purchase raw materials (wires, connectors, shielding layers, sheaths, etc.) according to BOM, and verify the compliance of materials (such as wire diameter tolerance, connector plating thickness) through incoming material inspection (IQC).
- Production planning and scheduling: Combined with the order quantity and equipment capacity (such as the daily capacity of the automated production line of 5,000 sets), formulate production schedules, and reserve inspection and rework buffer time.
- Process document solidification: Output the operating instructions (SOP), clarify the parameters of each process (such as terminal crimping pressure 30-35N, heat shrink tube heating temperature 120-150℃), and conduct pre-job training for operators.
2. Batch production and process quality control (IPQC)
- Automated production-oriented: The core processes (such as wire cutting, terminal crimping, shield layer welding) use automated equipment (such as CCD visual positioning crimping machine, robot branching system) to reduce manual errors.
- Key process monitoring:
- Terminal crimping: Real-time monitoring of crimping height and width (accuracy ±0.01mm), sampling every hour for tensile testing (≥80N).
- Shielding layer processing: Check the coverage of the braided mesh (≥95%) and the aluminum foil is fitted without bubbles.
- Connector assembly: Verify the locking force (≥5N) and the waterproof sealing ring is installed in place.
- Online detection: Use a continuity tester to 100% detect the conductivity of the wiring harness and eliminate short-circuit and open-circuit defective products.
3. Finished product inspection (FQC)
- Sampling inspection is carried out according to AQL standards to verify the appearance (no damage, clear marking), size (branch length tolerance ±5mm), electrical performance (such as high-frequency signal transmission eye diagram test), and environmental adaptability (random sampling of samples for repeated high and low temperature tests).
- Issue a finished product inspection report, and qualified products enter the packaging stage (anti-static bags, turnover boxes, with certificates and traceability labels).
V. Delivery and after-sales service stage
Ensure that the product is delivered on time and provide full life cycle technical support.
1. Delivery and logistics
- Ship according to the delivery method required by the customer (such as express delivery, logistics dedicated line), with a packing list (including product quantity, batch number, inspection report).
- Provide traceability documents: Each batch of products is accompanied by a batch traceability sheet, recording the raw material batch, production equipment, operator, and inspector information for subsequent quality traceability.
2. After-sales service
- Response to quality issues: If customers report quality issues (such as signal interference, loose connectors), we will respond within 24 hours and issue an analysis report within 48 hours (such as failure analysis to determine that the shielding layer is poorly welded).
- After-sales guarantee: Provide warranty services according to the contract agreement (such as free replacement of defective products for 1 year), and initiate rework or recall processes for batch problems.
- Continuous improvement: Collect customer feedback and incorporate it into the continuous improvement (CI) system (such as optimizing the shielding layer structure of a certain model of wiring harness to improve anti-interference ability).