Tag
Harness
- TM5 November 2026Terminals that back out: checking they are fully seatedA terminal short of its lock still passes continuity. How to prove seating in every cavity, what a sample cannot find, and what 15 UK recalls say about locks.
- TQ5 November 2026First pass yield in harness assembly: how to count itHow to count FPY on an assembly line: one unit definition, first result only, rework as a fail. Crimp yield tables, rolled yield, DPMO and a one-page log.
- TQ5 November 2026AQL sampling on harnesses: what passes, when to test 100%Exact odds for AQL 1 sampling show a lot 5% defective can still pass. What the plan protects, what c=0 changes, and when to replace sampling with a 100% test.
- TM5 November 2026Crimp pull test: how many, how often, what to do on a failScored pass or fail, three clean pulls only rule out a process over 63% weak. Read the failure mode, set the interval from your quarantine limit.
- TQ5 November 2026Harness testing: what continuity, 4-wire, IR and hipot missWhich electrical test catches which harness fault, and which cannot. A fault-by-test matrix, capacitive current and stored-energy figures, and HSE limits.
- TM5 November 2026Crimp height: what it shows and how tightly to control itCrimp height shows the tool closed where it should, not that the crimp is good. Tolerances, micrometer error, Cpk at small samples and a response table.
- HB5 November 2026AWG to mm²: which metric wire, and what rounding down costs1 mm² replaces 18 AWG. 0.75 mm² is 8.9% short by area and can be 20% worse on data sheet resistance. AWG table, real strandings, terminal traps, a rule.
- TQ5 November 2026Wire harness failures: what 422 UK vehicle recalls showOf 4,566 UK vehicle recalls from 2016 to 2025, 422 trace to wiring. Routing and loose bolted joints lead by count, fretting by vehicles listed.
- HB5 November 2026Wire harness manufacturing: each stage and how it is checkedThe eight stages of a wire harness build, also called a wiring loom, the fault each stage can leave behind, and the check that finds it before shipping.