Wiring Harness Course

Lesson 1 • Core Components and Materials

Identifies wires, connectors, terminals, and protective materials used in harnesses. Connects material selection to performance and durability requirements.

Lesson 2 • Introduction to Wiring Harnesses

Defines wiring harnesses and their function in bundling electrical conductors. Establishes the baseline vocabulary used throughout the course.

Lesson 3 • Workplace Safety and Tool Awareness

Covers personal protective equipment, electrical hazards, and safe handling of harness materials. Establishes safety habits required before hands-on work begins.

Lesson 4 • Electrical Fundamentals for Harness Work

Reviews voltage, current, resistance, and circuit concepts essential for harness design. Provides the electrical theory needed for all subsequent chapters.

Lesson 1 • Bill of Materials and Parts Lists

Teaches extraction of part numbers, quantities, and specifications from BOMs. Links BOM data to procurement and assembly planning activities.

Lesson 2 • Schematic Symbols and Conventions

Introduces standardised symbols for wires, connectors, grounds, and devices. Accurate symbol recognition is the prerequisite for all diagram interpretation tasks.

Lesson 3 • Harness Drawings and Formboards

Covers 2D harness drawings, formboard layouts, and dimensional callouts. Connects drawing data to physical harness geometry and branch routing.

Lesson 4 • Engineering Change and Revision Control

Explains how engineering changes are documented and incorporated into drawings. Ensures students work from current revisions and avoid obsolete specifications.

Lesson 1 • Automated Wire Processing Equipment

Introduces programmable wire processing machines for high-volume production. Students understand machine setup, programming basics, and output quality verification.

Lesson 2 • Wire Measurement and Cutting

Covers accurate length measurement, cut-to-length techniques, and tolerance requirements. Precise cutting reduces waste and ensures harness dimensional accuracy.

Lesson 3 • Wire Identification and Marking

Covers colour coding, sleeve marking, and label application methods for wire identification. Accurate marking enables efficient assembly, testing, and maintenance.

Lesson 4 • Wire Tinning and Conductor Preparation

Explains tinning of stranded conductors and pre-twisting techniques for termination. Proper conductor preparation prevents fraying and improves solder joint quality.

Lesson 1 • Specialty Termination Methods

Introduces IDC, ultrasonic welding, and press-fit terminations used in specific applications. Expands student capability beyond standard crimp and solder methods.

Lesson 2 • Soldering Terminals and Splices

Teaches soldering techniques for cup terminals, splice sleeves, and wire-to-wire joints. Solder connections must meet workmanship standards for fillet shape and coverage.

Lesson 3 • Crimp Termination Fundamentals

Explains crimp zone anatomy, crimp height, and pull-force requirements. Correct crimping is the most common termination method and the basis for quality harnesses.

Lesson 4 • Crimp Tool Selection and Calibration

Covers hand tools, bench presses, and applicator dies for various terminal sizes. Tool calibration and die maintenance directly affect crimp quality and consistency.

Lesson 1 • Harness Dimensional Verification

Teaches measuring branch lengths, connector positions, and overall harness geometry against drawings. Dimensional conformance is verified before the harness leaves the formboard.

Lesson 2 • Bundling and Lacing Techniques

Covers spot ties, continuous lacing, and cable tie application for bundle integrity. Consistent bundling maintains harness shape and prevents wire migration.

Lesson 3 • Splice and Junction Point Assembly

Covers inline splice construction, junction block wiring, and splice sleeve placement. Splices must be positioned and insulated to maintain harness flexibility and reliability.

Lesson 4 • Formboard Layout and Wire Routing

Teaches placing wires on a formboard according to harness drawings and routing sequences. Correct routing order prevents rework and ensures branch geometry accuracy.

Lesson 1 • Routing and Packaging Constraints

Applies routing rules for bend radius, clearance, and separation from heat and fluid sources. Routing decisions directly affect harness durability and electromagnetic compatibility.

Lesson 2 • Electromagnetic Compatibility in Design

Introduces shielding, twisted-pair routing, and grounding strategies for EMC compliance. EMC design prevents interference between harness circuits and surrounding systems.

Lesson 3 • Connector and Terminal Selection

Covers connector current rating, environmental sealing, and mating cycle requirements. Selection criteria align connector capability with application demands and service life.

Lesson 4 • Wire Gauge and Current Capacity Selection

Teaches ampacity tables, derating factors, and voltage drop calculations for wire sizing. Correct gauge selection prevents overheating and ensures circuit performance.

Lesson 1 • Insulation Resistance and Hi-Pot Testing

Explains insulation resistance measurement and high-potential dielectric testing methods. These tests detect insulation degradation and prevent in-service electrical failures.

Lesson 2 • Continuity and Resistance Testing

Covers point-to-point continuity checks and resistance measurement using meters and test fixtures. Identifies open circuits, shorts, and high-resistance connections before installation.

Lesson 3 • Functional and Signal Integrity Testing

Introduces functional test boards, signal injection, and data bus verification methods. Confirms that harness performance meets system-level electrical requirements.

Lesson 4 • Non-Conformance and Corrective Action

Covers defect classification, non-conformance reporting, and root cause analysis processes. Students learn to disposition defects and prevent recurrence through corrective actions.

Lesson 1 • Lean Principles in Harness Manufacturing

Applies 5S, value stream mapping, and waste elimination to harness production lines. Lean tools reduce lead time and improve floor-level efficiency and organisation.

Lesson 2 • Statistical Process Control for Harness Lines

Introduces control charts, process capability indices, and sampling plans for harness processes. SPC data enables proactive quality control before defects reach the customer.

Lesson 3 • Production Planning and Work Sequencing

Covers work order interpretation, assembly sequence planning, and workstation balancing. Effective sequencing reduces cycle time and minimises work-in-process inventory.

Lesson 4 • Traceability and Production Records

Establishes lot traceability, serialization, and production record requirements for harness assemblies. Complete records support warranty analysis, recalls, and continuous improvement.