Wire Harness Course

Lesson 1 • Reading Electrical Schematics

Teaches interpretation of wiring diagrams and schematic symbols used in harness documentation. Connects drawing literacy to accurate harness assembly.

Lesson 2 • Industry Standards and Specifications

Introduces the regulatory and quality frameworks governing harness design and manufacture. Explains how standards drive material and process decisions.

Lesson 3 • Workplace Safety Fundamentals

Covers electrical hazards, hand tool safety, and personal protective equipment relevant to harness work. Establishes safe habits before hands-on activities begin.

Lesson 4 • Harness Components and Materials

Identifies conductors, insulation, connectors, terminals, and protective sleeving. Links material selection to electrical and environmental performance.

Lesson 1 • Wire Cutting to Length

Covers manual and automated cutting methods and tolerance requirements. Accurate cut lengths reduce rework and material waste in downstream assembly.

Lesson 2 • Conductor Tinning and Twisting

Explains when tinning and wire twisting are required and how to perform them correctly. These processes improve solderability and reduce electromagnetic interference.

Lesson 3 • Wire Marking and Identification

Covers ink printing, heat-shrink labeling, and color-coding systems for wire identification. Consistent marking supports accurate assembly and field troubleshooting.

Lesson 4 • Handling and Storage of Prepared Wire

Addresses contamination prevention, coiling methods, and shelf-life considerations for prepared conductors. Proper storage maintains quality before assembly begins.

Lesson 1 • Crimp Quality Inspection

Teaches visual, dimensional, and destructive inspection methods for crimped terminals. Inspection criteria are tied directly to industry pull-force and cross-section standards.

Lesson 2 • Splice and In-Line Terminations

Covers crimp splices, butt connectors, and in-line splice techniques for joining conductors. Splices must meet the same electrical and mechanical standards as terminal crimps.

Lesson 3 • Crimp Tooling Selection and Setup

Covers hand tools, pneumatic presses, and applicator dies for various terminal families. Correct tooling setup prevents defects and ensures repeatable crimp quality.

Lesson 4 • Performing the Crimp Operation

Provides step-by-step crimping procedure including wire insertion depth and actuation technique. Consistent technique is the foundation of a reliable electrical connection.

Lesson 1 • Connector Assembly Verification

Covers continuity checks, cavity population audits, and TPA engagement verification. Verification at this stage prevents costly defects in later harness assembly.

Lesson 2 • Terminal Extraction and Rework

Explains the use of extraction tools to remove terminals without housing damage. Rework procedures preserve housing integrity and reduce scrap costs.

Lesson 3 • Terminal Insertion Techniques

Teaches correct insertion direction, force application, and audible or tactile confirmation of seating. Proper technique prevents bent terminals and incomplete seating.

Lesson 4 • Connector Sealing and Environmental Protection

Covers wire seals, cavity plugs, and connector-level sealing for harsh environments. Sealing integrity is critical for automotive, aerospace, and outdoor applications.

Lesson 1 • Dimensional and Visual Inspection on Board

Teaches length measurement, connector position checks, and visual defect identification on the formboard. On-board inspection catches errors before harness removal.

Lesson 2 • Formboard Design and Setup

Explains formboard construction, peg placement, and drawing overlay methods. A correctly set up formboard is the template for consistent harness geometry.

Lesson 3 • Breakout and Branch Point Construction

Covers forming, taping, and securing branch points where sub-harnesses diverge. Properly constructed breakouts resist pull-out forces and maintain bundle geometry.

Lesson 4 • Bundling and Cabling Techniques

Teaches lacing, cable ties, and spiral wrap methods for securing wire bundles. Bundle integrity affects harness durability and installation ease.

Lesson 1 • Grommets, Clips, and Mounting Hardware

Covers installation of grommets, P-clips, and mounting brackets that secure harnesses in assemblies. Proper hardware prevents chafing and vibration-induced fatigue.

Lesson 2 • Braided and Expandable Sleeving

Teaches installation of braided, expandable, and corrugated sleeving over harness branches. Sleeving provides abrasion resistance and a finished appearance.

Lesson 3 • Heat-Shrink Tubing Application

Explains heat-shrink selection, shrink ratios, and proper heat application technique. Correct shrink application seals, insulates, and mechanically protects terminations.

Lesson 4 • Conduit and Corrugated Tubing

Covers rigid and flexible conduit installation for high-abrasion or high-temperature zones. Conduit protects harnesses routed through harsh mechanical environments.

Lesson 1 • Harness Testing Principles

Introduces test objectives, test coverage concepts, and the relationship between test methods and defect types. Understanding test theory guides selection of appropriate test strategies.

Lesson 2 • Functional and Signal Integrity Testing

Covers end-to-end functional tests and signal integrity checks for data and shielded circuits. These tests validate harness performance in the context of the end system.

Lesson 3 • Insulation Resistance Testing

Teaches high-voltage insulation resistance measurement to detect insulation breakdown. Test voltage selection and minimum resistance thresholds are defined by specification.

Lesson 4 • High-Potential (Hi-Pot) Testing

Explains dielectric withstand testing to verify insulation integrity under elevated voltage. Safe test setup and operator precautions are emphasized alongside procedure steps.

Lesson 1 • Quality Management in Harness Production

Introduces quality management principles, inspection plans, and control plans specific to harness manufacturing. A structured quality system prevents defects from reaching the customer.

Lesson 2 • Statistical Process Control Basics

Introduces control charts, process capability indices, and sampling plans for harness processes. Data-driven monitoring detects process drift before defects are produced.

Lesson 3 • Defect Classification and Reporting

Defines critical, major, and minor defect categories and explains non-conformance reporting procedures. Accurate classification drives correct disposition and corrective action priority.

Lesson 4 • Continuous Improvement in Production

Covers lean manufacturing principles, 5S workplace organization, and kaizen events for harness lines. Sustained improvement reduces waste and increases throughput without sacrificing quality.