Harness unqualified product control plan

The wiring harness is an important part of the automobile control circuit. The detection and processing of the automobile wiring harness is an important measure to ensure the safety of the automobile. Its structure is formed by crimping copper terminals and wires, and then wrapped by a sheath connected to an insulator, including circuits, insulators, and connectors. three parts.

The process engineer and quality engineer of the wire harness factory are both responsible. They must understand the industry standards and the requirements of the wire harness drawings and understand the purpose of the wire harness. When dealing with problems on site, be clear-headed to ensure that the product has no safety hazards. We advocate that the handling of on-site problems should be supported by standards and data, combined with various cases to handle them thoroughly at one time; the decision should be accurate, and various risks should be avoided.

The processing methods for the control of unqualified products in the process: 1 Rework; 2 Rework; 3 Scrap; 4. Concession acceptance.
For example: a wire harness factory has the phenomenon that the imported terminal 12048451-DELPHI is returned in the sheath 12052613-DELPHI when it is turned on. The quality department notified the workshop to investigate the bad risk of more than 30 boxes of finished products in the inventory, and found that all black 2.0mm wires were crimped The terminal will leave the space of the sheath after a little force is applied. The operator consciously uses an awl to place the terminal lock plate above 30° before returning the part, and this height is obviously unreasonable (the height is greater than that of an uncrimped one on site The entire terminal is 0.5mm); ②It is found that the black wire terminal has the same name as the red wire terminal inserted in the other hole, the thickness of the male terminal insertion part is 0.825mm, and the female terminal has a gap greater than 1mm. The insertion and extraction force does not conform to the standard. In order to avoid the dual risks of terminal return and poor contact, personnel should first require repairing two locations for each terminal in the workshop, and then check the root cause; (attached: QC/T 417.3-2001 Automotive Wire Harness Connector Part 3: Single Wire Chip-type connector plug-in force performance requirements)

The technicians went to the site to give instructions: "As long as you don't return the parts." The workshop operator couldn't figure out who to listen to. After repairing two places, they stopped repairing one part. Later, it was found that the purchase channels of the two batches of terminals were not the same (it is said that the crimping of the black wire is the high imitation part not good). This technician dared to say let go of unverified terminals with almost zero pull-out force during insertion. He was so courageous, or he didn’t understand, he didn’t deal with problems thoroughly, and he didn’t know anything about industry standards.

③The official website shows that the maximum tolerance wire diameter of this terminal is 1.25mm, and the actual crimping is 2.0 mm. When the technician encounters unreasonable and risky problems, they do not communicate with the OEM for rectification. The answer is: This has been used for several years, and the leakage of copper wire will not affect Yes, the pulling force is enough. I advise you not to take a fluke. Sooner or later, the problem is the fault of the harness factory. If you know that there is a problem, you can't rectify it, and you can't escape the responsibility. The crimping of the same terminal shows that three aspects are bad. The problem is so serious. As a wiring harness factory technician, you must dare to be a big responsibility. If you don't control the control, it hurts the boss and ultimately hurts himself. Just imagine, if your car uses such a harness, would you still dare to go on the road? With such a small wiring harness circle and such a working style, will anyone dare to use you in the future?

With the rapid development of the automobile industry and the improvement of people's living standards, the number of private cars is increasing day by day, and the safety performance of cars affects the quality of people's daily life. Automobile wiring harness failure is one of the more common failures in automobile failures. Process and quality engineers should control the quality of the automobile wiring harness itself and the correctness of the line connection, understand the types and causes of automobile wiring harness failures, and use correct judgment methods Rework and repair or scrap the defective products in the process of production to ensure the safe driving of the car.

Common automotive wiring harness faults include: poor contact of connectors, short circuits, short circuits, wrong paths, grounding, etc. between cables.

From the perspective of the vehicle, the wiring harness mainly connects the various electrical systems of the vehicle. The layout, function, process materials, production process and other problems of the wiring harness, and the quality of terminal crimping affect the quality of the vehicle.

The definition of rework: the measures taken to make the nonconforming product meet the specified requirements.

The definition of repair: Although the product still does not meet the requirements of the original regulations, the measures taken to make it meet the intended use.

Note: When the product is reworked/reworked, the reviewer should determine the corresponding rework content according to the type of product defect, and move the product to be reworked to the rework area, and then the designated reworker will perform the corresponding rework operation according to the review comments.

1. Problems caused by wiring harness
① Part or all of the electrical functions fail;

② The whole vehicle cannot drive normally;

③ Part of the connector is ablated;

④ Short circuit inside the wiring harness;

⑤ Partial wear of wiring harness;

⑥ Local ablation of the wiring harness;

⑦ The whole vehicle is ablated.

Two, the main problem of the wiring harness
① The size does not match

a. Wire size does not match; b. Hose size does not match; c. Branch size does not match; d. Clasp size does not match; e. Others.

② Poor assembly

a. Remove the nail; b. Insert the wrong wire; c. Incorrect direction; d. The fixer is not strong; e. The accessories fall off; f. Others.

③ Poor bandaging

a. The wires are not neat; b. The wires are leaking; c. The tape is tilted; d. The bandage is not firm; e. Others.

④ Poor crimping

a. Bad terminal; b. Bad terminal position; c. Exposed core wire; d, C/H, I/H inconsistency; e. Terminal wire does not fit; f. Others.

⑤ Defects

a. Under-voltage terminal; b. Under-insertion sheath; c, under-wrapped tape; d, under-hose; e, under-labeling; f, under-fuse; g, under-buckle; h, under-fixer; i, under-fitting ; J, other.

⑥ Defective items

a. Bad wire; b. Bad terminal; c. Bad hose; d. Bad sheath; e. Bad label; f. Bad accessories; g. Others.

⑦ Wrong product

a. Wrong wire; b. Wrong terminal; c. Wrong waterproof plug; d. Wrong hose; e. Wrong label; f. Wrong sheath; g. Wrong fitting; g. Others.

Third, the wiring harness process control problem
3.1 Incoming inspection
Qualified: Incoming material inspection will judge the quality of incoming materials according to the corresponding inspection standards, and mark the quality of the inspected raw materials after being qualified. Sign the qualified seal on the corresponding inspection form and notify the warehouse clerk to go through the storage procedures.

Unqualified: When the incoming material is judged to be unqualified, the incoming inspection will mark the unqualified material and first notify the warehouse clerk to move the unqualified product to the corresponding control area, and fill in the "Quality Feedback Form" to purchase parts quality problems The notice informs SQE and customer representatives (customers provide products).

3.2 Rework of non-conforming products
The reworker shall notify the inspector to carry out the inspection, and the inspector shall perform the inspection in accordance with the "Product Rework/Inspection Operation Guide". After the inspection is passed, the inspector will remove the red card and record the result;

3.3 Verification
Inspectors must control and appraise all products during production and operation, and verify the consistency of material specifications and operation steps with process requirements;

3.4 troubleshooting
When there are suspicious materials/products, the inspector and the production team leader and the quality control team leader shall convene relevant personnel within two hours to inspect and trace the semi-finished products and finished products.

3.5 Suspicious materials/products not shipped
The quality control team leader, inspector, shift leader, production department supervisor, and logistics supervisor will conduct traceability based on the batch number of suspicious materials/products and related records (inspection records, warehousing records, turnover cards, etc.), and ensure traceability to the company The initial suspicious batch prevents the reordering or shipment of substandard products to customers.

3.6 Suspicious materials/products have been shipped
The sales department is responsible for notifying customers, and traces them together with the quality control team leader, shift leader, production department supervisor, and logistics supervisor based on the batch number of the suspicious material/product and related records (inspection records, warehousing records, delivery records, etc.). If the initial suspicious batch cannot be determined, it can be traced back to the latest batch of suspicious materials/products that have not been complained by customers. Materials/products that have exceeded the warranty period may not be traced temporarily. Any unqualified product related to product safety shall be reported to the sales department by the quality control team leader who fills in the "Quality Feedback Form", and the sales department leader negotiates with the customer and takes remedial measures, and returns the product if necessary.

4. Control method and purpose
The number of non-conforming units is within 1-50 units: the inspector will register the non-conforming products in the "Statistical Table of Non-conforming Products", the team leader will fill in the person in charge, briefly describe the reason for the non-conformity, and the reworker authorized by the Quality Department will rework Rework in the area; ≥50 unqualified units: the inspector will immediately identify (red mark/card) to isolate and notify the quality control team leader. The quality control team leader will convene a multi-functional coordination team to verify and analyze the products with quality defects Reasons, identify various unsafe risks, review the treatment plan, and fill in the final treatment result on the red card or "Non-conforming Product Review and Disposal Form". The treatment process is carried out according to the five-step method or 8D report. After the measures are completed, the inspector will Retrieve the red card to the quality control team leader for statistical analysis of quality data. The monthly "Statistics of Non-conforming Product" and the red card or the "Disqualified Product Review and Disposal Form" will be submitted to the quality control team leader for statistical analysis as the basis for formulating a priority reduction plan; whether you are a process technician or quality Engineers must treat today's product quality as our tomorrow's market.