Testing & quality
Continuity, insulation and hipot testing, inspection, sampling, yield, defects, and how to use the standards on the line.
Start hereHarness 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.
- 5 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.
- 5 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.
- 5 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.