Our Customized Process
JinHai Customized Wiring Harness Service Process: Full-cycle management from concept to reliable connection, specifically divided into the following six core stages:
Stage One: In-depth Requirements Analysis and Technical Discussion
1. Initial Contact and Requirements Research:
Customer-provided information: We welcome any form of requirement specification from customers, including but not limited to: basic functional descriptions, application environments (e.g., automotive, industrial robotics, medical devices), preliminary schematics, block diagrams, 2D/3D layout drawings, prototypes, or competitor samples.
Technical Parameter Consultation: Our engineers will engage in detailed discussions to clarify key specifications:
Electrical Performance: Voltage, current, signal type, shielding requirements, impedance control, etc.
Mechanical Performance: Bend radius, tensile strength, vibration/shock resistance, mounting methods.
Environmental Requirements: Operating temperature, humidity, oil resistance, chemical corrosion resistance, waterproof rating (IP rating), flame retardancy rating (UL/CE).
Regulations & Standards: Mandatory industry standards (e.g., ISO 9001, IATF 16949, TL 9000, IPC/WHMA-A-620) and safety certifications (UL, CE, CCC).
2. Project Feasibility Analysis and Preliminary Proposal:
Based on collected information, our engineering team conducts a preliminary technical review to assess manufacturing feasibility, potential risks, and cost structure.
Deliver a preliminary Technical Proposal and Specification Recommendation, including recommended connectors, wire types, wire gauges, color coding, and a general budget range.
Phase Two: Collaborative Design and Engineering Development
This phase forms the core of customization, where we work closely with clients to transform concepts into manufacturable engineering files.
1. Schematic and Routing Diagram Verification:
Based on schematics provided by the client or co-developed with us, we perform detailed harness routing design to ensure circuit logic accuracy.
2. 3D Modeling and 2D Drawing Creation:
3D Modeling: Create a 3D digital prototype of the harness using professional software (e.g., CATIA, SOLIDWORKS). This enables:
Virtual interference checks with surrounding components.
Precise measurement of harness length and routing.
Optimized routing paths for easy assembly and maintenance.
2D Engineering Drawings: Generate two-dimensional drawings for production guidance and inspection, including:
Wire harness assembly drawings and sub-assembly drawings.
Wire/terminal crimping diagrams.
Bill of Materials (BOM).
3. Design Review Meetings:
Organize joint design reviews involving cross-functional teams (Design, Process, Quality, Production) and the customer.
Collectively confirm all design details, finalize the design version, and sign the Design Review Form.
Phase Three: Sample Production and Validation Testing
“Validate first, then mass-produce” is the key principle for ensuring quality.
1. Rapid Prototyping:
Produce a small quantity of engineering samples (Prototypes) using processes and standards identical to mass production.
Samples undergo comprehensive identification and documentation for traceability.
2. Comprehensive Testing and Validation:
Electrical Testing: 100% continuity testing, insulation withstand voltage testing, resistance testing.
Mechanical Testing: Pull-out force testing, connector insertion/extraction force testing, bending testing.
Environmental Testing (as required): Temperature cycling, salt spray testing, water/dust resistance testing (IP rating), vibration testing.
Dimensional Inspection: Verify critical dimensions against 2D drawings using tools like CMM coordinate measuring machines.
3. Customer Sample Approval:
Deliver test reports and samples to the customer for installation testing and functional verification.
Obtain the customer-signed Sample Approval Report, signifying final product design confirmation.
Phase Four: Supply Chain Management and Production Preparation
To ensure stable mass production, we strictly control the upstream supply chain and prepare for manufacturing.
1. Material Procurement and Verification:
Purchase raw materials (wires, connectors, terminals, sleeves, etc.) from qualified suppliers (AVL) based on the confirmed BOM.
Conduct incoming material inspection (IQC) on all incoming materials to ensure compliance with specifications.
2. Production Tooling and Documentation Preparation:
Prepare specialized production tooling, such as crimping dies, test boards, wiring boards, or fully automated production lines.
Distribute comprehensive production guidance documents, including Standard Operating Procedures (SOP), Inspection Specifications (SIP), and test protocols.
Phase Five: Lean Production and Full-Process Quality Control
Integrate quality assurance into production rather than relying on post-production inspection.
1. Standardized Production Processes:
Wire Cutting + Terminal Crimping: Utilize fully automated cutting/crimping machines to ensure precise wire cutting, crimp height, and pull-out force meet standards like IPC/WHMA-A-620.
Pre-assembly: Perform sub-assembly and winding/wrapping on wiring boards.
Final Assembly: Complete final assembly and housing installation.
2. Full Process Quality Control (IPQC):
First Article Inspection: Comprehensive inspection of the first product at the start of each shift or new work order.
Routine Inspections: Quality engineers conduct periodic spot checks on critical production processes (e.g., crimping, waterproofing).
100% In-Line Electrical Testing: Every harness must pass a defined electrical test program before packaging to ensure zero defects upon shipment.
Phase Six: Final Inspection, Delivery & After-Sales Service
Project completion and ongoing support.
1. Final Inspection (OQC/FQC):
Conduct final random checks on finished products for appearance, dimensions, and packaging, issuing a Factory Inspection Report.
2. Packaging & Delivery:
Customized packaging using anti-static, scratch-resistant, and moisture-proof materials per customer requirements.
Provide clear labeling with barcode/RFID management support.
Deliver on time per agreed logistics plan.
3. After-Sales Service and Ongoing Support:
Provide complete technical documentation packages (e.g., drawings, BOM, test reports, certificates).
Establish customer profiles with regular follow-ups.
Offer rapid-response technical support and value-added services like production capacity reserves or VMI (Vendor Managed Inventory) based on customer needs.
JinHai's Service Philosophy:
We are not merely a wire harness manufacturer, but a strategic extension of your project team. Through this rigorous, transparent, and highly collaborative customized service process, we are committed to becoming your most trusted partner, working together to ensure every connection is safe, reliable, and efficient.
Contact Custom Cable & Harness Assemblies today for customized services
Contact us today to find out how we can fulfil your cable and wire harness needs.
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