International Journal of Electronics and Modern Technology

May 2015, Vol-01, Issue-03, pp.:1-6

Carthage Science Publishing
www.cs-publishing.com

Digital Technology Use Instead of Hardcopies

During Pre-Assembly Operation of Wiring
Harness Production
Rt GNTRKN1,*, N.aatay STNDA2, Bnyamin KAYA3 and Burcu DEMRELL4
1
Dumlupnar University, Simav Technology Faculty, Simav Ktahya / Trkiye
2,3,4
Nursan Wiring Harness R&D Center, Tavanl Ktahya / Trkiye
*Contact: rustu.gunturkun@dpu.edu.tr

Abstract In the scope of this study, pre-assembly operation in the wiring harness manufacturing factory is
improved. By using digital technology during pre-assembly operation, possible operator mistakes and quality
problems due to confusion of hardcopy documents are prevented and correct part production is provided. Uploading
pre-assembly operation sheets into the system is enabling operators to reach the required documents quickly as well
as reducing manpower time loss caused by printing and distribution of hardcopy documents. As a result of this
application, 74% time saving and annual 254.524 number A4 size paper and indirectly tree saving are provided. In
addition to saving, operator mistakes are 47, 77% improved. In other words, Company related expenses are decreased
from 10220$/year to 442, 5$/year.
Two interfaces are designed for software. The first interface is used by designer for uploading more than 3000 type of
designed pre-assembly operation sheets to system. Second interface is used by operator for displaying the required
pre-assembly operation sheets from the system. In order to provide ergonomic use of the devices by the operators, 3
axis movable tpe of telescopic hangers are installed.
Keywords: Wiring Harness, Production, Software, Environment, Saving, Mistake

Rt GNTRKN et al., IJEMT, 2015, Vol(1)-Issue(3)

Telescopic hanger is preferred for LCD screen and atom
computer installation. Hanger is 3 axis movable type which
provides ergonomic working conditions for the operators.
Number of hangers are in parallel to number of options
produced in the production lines.

I.
INTRODUCTION
Wiring harness is one of the most important parts in the
vehicle after engine and transmission. Wiring harness, like
nerves of a human being, has main role in the transfer of
electrical signals, operation of the functional and safety parts.
Although wiring harness cannot be seen easily out of engine
room, they are one of the most critical parts as they are
assembled in the beginning stage of vehicle assembly and
enable the operation of all vehicle functions. Due to earlier
assembly of wiring harness, repair may require disassembly of
many parts assembled on it when there is a quality problem.
After vehicle, wiring harness is the first coming part that is
subject to biggest BOM including different type of sub parts,
many engineering modifications in parallel to improvements
and manpower requirement during production. Considering
significance and manpower requirement in the production
process, any studies decreasing quality problems and cycle
time is having significant and key role in the competitive
market in the aspect of cost, safety and comfort. [1]
All wiring harness type has independent assembly
production line and a production loop inside the line [2]. Each
conveyor line is working like a loop system on which
assembly tables are located as a working station of the
operators and wiring harness assembly production is
completed when a loop is completed [3]. Conveyor is moving
production line and carries between 22 and 25 wiring
assembly tables. There are pre-assembly working stations in
parallel to one side of conveyor. The operators should check
all pre-assembly operation sheets before each production [4].
These documents are including socket scheme and wire
assembly position on the connectors. Sample connector
scheme is given in figure 4.1.

Fig. 2.2. Telescopic Hanger

PROGRAM / SOFTWARE
Using the method of application program interface is
designed according to the industry common workflow with
Visual Basic [6] interface program considering work flow.
This interface program is including name of production line,
part number and number of pre-assembly operation sheet
(Figure 3.1). Operators can easily reach and display required
sheets by using designed program. However, operators dont
have any permission to reach other line sheets or to change
information on the sheets.

II.
DEVCE & EQUPMENTS
In accordance with operation flow, almost has a great
computer features and ease of use of space-saving mini
computers [5], 18,5 inch LCD screen and mouse is preferred
considering easier and modular use.

Fig. 3.1 Interface Program Display Used By Operators

There is another interface for the designer to upload the

required pre-assembly operation sheets to system. Designers
are authorized to change the production line name, part
number and pre-assembly operation sheet (Figure 3.2).
Fig. 2.1. LCD Screen

Rt GNTRKN et al., IJEMT, 2015, Vol(1)-Issue(3)

addresses as second address connector may consist of various
addresses which require another module operation. All module
schemes has numbers to be followed and distributed by
operators easily. Module schemes and connector drawings are
designed with DESIGNCAD program. Wire colour, code and
address information should be included in the module schemes
for correct pre-assembly operation.
IV.

GENERAL STRUCTURE AND OPERATON OF

SYSTEM
All designs are uploaded to server which currently can
provide 92 ea module scheme data flow for pre-assembly
operation (Figure 5.1). A software is developed which enable
designers to manage module schemes and operators to display
the module schemes with atom computers & screens from (the
database of) the server [8].

Fig. 3.2 Interface Program Display Used By Designer

III.

PRE ASSEMBLY OPERATON SHEET

Fig.4.1. (ekil) Sample Pre Assembly Scheme

Pre-assembly operation sheets are including a connection

diagram of various connectors named as module within the
factory. These modules are the beginning and basic parts of
the wiring harness production. Technical drawing is the main
reference of the part production. Module scheme is derived
from technical drawings and designed for operators to
understand and use easily during production [7]. Module
scheme is showing wire code, wire colour, connection address
of the wires and other materials on the related connection area.
In order to prepare module scheme, wire circuit addresses and
related connectors are defined according to technical drawing.
Wire circuits have two connection point named as addresses.
Wires circuits having same addresses are determined and other
address of the circuits are considered in the design of the
module scheme. However scheme cannot include all circuit

Fig. 5.1. Data Flow From The Central Server

Wireless type atom computer, high resolution screen and

mouse on the telescopic hangers are used on pre-assembly
operation line for module scheme data transfer. Two interfaces
is developed in the software program. First interface is
working as system management and enables designer to
upload the documents to server (Figure 3.1). They can manage
documents for more than 3000 type of part numbers. Second
interface enables to reach and display the uploaded documents
from the server (Figure 3.2).
V.

REQUIRED D OCUMENT

Rt GNTRKN et al., IJEMT, 2015, Vol(1)-Issue(3)

The documents produced in Design CAD, should be
converted to JPEG or PDF format to be used in the software.
During try outs in the pre-assembly area, Operator feedbacks
related with JPEG formats was negative as they displayed later
than PDF format. Besides, PDF format easier use and
compatibility to developed interface program was better.
Therefore PDF format is selected in the study.

Fig. 6.2: Data Reading Flow

Process is started upon module change requirement for an

existing part or new module requirement in parallel to new
part. Required module scheme change or design is made with
Design Cad program. Module scheme is confirmed project
engineers and confirmed module schemes is transformed to
interface program format by designer and uploaded to system
database (server). Module scheme becomes ready to be used
upon format & display condition check in the system (Figure
6.1). As a second stage of this process, operators use related
interface program and select required module schemes to start
pre-assembly production in accordance with customer ordered
part numbers. Upon selection of the part number & module
number, required module scheme is diplayed on the screen
and operator start the right wires on the right connector

Fig. 6.1: Data Derivation Flow

Rt GNTRKN et al., IJEMT, 2015, Vol(1)-Issue(3)

assembly production as pre-assembly operation of part
production. (Figure 6.2).
VI.

CONCLUSION

In the scope of pilot application, Floor Wiring production line

is selected in Nursan Wiring Harness Factory considering the
experience years of the operators and Floor wiring lower
complexity (optional change). Also one shift is taken into
consideration during pilot application in order to conclude the
study and analyse the quick feedbacks. By using digital
technology during pre-assembly operation, possible operator
mistakes and quality problems due to confusion of hardopy
documents are prevented and correct part production is
provided. Uploading pre-assembly operation sheets into the
system is enabling operators to reach the required documents
quickly as well as reducing manpower time loss caused by
printing and distribution of hardcopy documents. As a result
of
this application, 74% time saving and annual 254.524 ea A4
size paper and indirectly tree saving are provided. In addition
to saving, operator mistakes are 47,77% improved. In other
words, Company related expenses are decreased from
23.098,053 TL/year to 1.000,05 TL/year. This application
provided operators to select and display correct pre-assembly
operation sheets on the screen easier than printed out and
distributed documents. Reaching correct information easily
results right wire assembly to right connector address and
reduce operator mistakes 47,77%. Digital technology use
decreased project technician time loss caused by printing out
and distribution of hardcopy documents. Time saving of
related personnel is around 74%. In the aspect of cost &
environment, 254.524 ea/year A4 size paper use (indirectly
tree saving) and related cost is decreased from 10220$/year to
442,5$/year.

Fig. 7.2. Pre-Assembly Scheme Hanger after Application

VII.

REFERENCES

[1] Performances of Wire Harness Assembly Systems. E.

Aguim and B. Raucent
[2] Justinas Tilindis and Vytautas Kleiza / Procedia CIRP 19 (
2014 ) 129 134 (The effect of learning factors due to low
volume order fluctuations in the automotive wiring harness
production.)
[3] zcan Uur, Peker Ahmet 2007. Kark Modelli U-Tipi
Montaj Hatlarnda Hat Dengeleme Ve Model Sralama
Problemleri in Yeni Bir Sezgisel Yaklam Gazi niv.
Mh. Mim. Fak. Der. Cilt 22, No 2, 277-286
[4] Justinas Tilindis and Vytautas Kleiza / Procedia CIRP 19 (
2014 ) 129 134 (The effect of learning factors due to low
volume order fluctuations in the automotive wiring harness
production.)
[5] http://atlas.selcuk.edu.tr/1205312/Computer
[6] Dukovic, J.M. ; Joyce, D.T. Computers and
Communications, 1995., Conference Proceedings of the 1995
IEEE Fourteenth Annual International Phoenix Conference on
DOI: 10.1109/PCCC.1995.472470 Publication Year: 1995 ,
Page(s): 346 351
[7] Karagz Yaar, Makine Mhendisliinde Bilgisayarla
Tasarm ve izim Oluturulmasnda kullanlan Autocad
Programlar. Mhendis ve Makina - Cilt: 41 Say: 481
[8] A proposal of DNS-based adaptive load balancing method
for mirror server systems and its implementation Yokota, H. ;
Kimura, S. ; Ebihara, Y. Advanced Information Networking
and Applications, 2004. AINA 2004. 18th International
Conference on Volume: 2DOI:
10.1109/AINA.2004.1283788 Publication Year: 2004 ,
Page(s): 208- 213 Vol.2

Fig. 7.1. Pre-Assembly Hanger Before Application

Rt GNTRKN received his Bachelors

degree in Electric and Electronic Teaching from
the Gazi University, Ankara, Turkey in 1991. He
completed his Master's degree in Gazi University
Ankara in the years 1997 and PhD degree in
Sakarya University Sakarya in the year 2003. At
Present he is working as an Associate Professor
Dumlupnar University Simav Technology
Faculty Electrical and Electronic Engineering. He
published more than 40 International Journals,

Central data and correct information display reduced

quality mistakes and increased efficiency of the operators. In
order to provide ergonomic conditions, telescopic type PC
hanger is used. Improved ergonomic conditions increased the
working satisfaction and efficiency of the operators and
decreased the possibility of physical diseases due to working
conditions.

Conferences and Articles.

Rt GNTRKN et al., IJEMT, 2015, Vol(1)-Issue(3)

Necati Cagatay Ustundag graduated from
Mechanical Engineering of Sakarya University and
completed his postgraduate education in Yildiz
Technical University. Besides his engineering
education, he gained bachelor degree in Business
Administration & Management andcompleted
MBA program in Gebze High TechnologyInstitute.
Since thestarting time of his professionalcareer in
1998, Mr. Ustundag succeeded in various
international projects and became professional in automotive sector. During
his long-term automotive experience, he worked for part development and
R&D departments in Turkey and abroad. He is currently working as
Engineering and R&D director in Nursan Wiring Harness Co. which is one of
the oldest and biggest supplier groups in Turkey

Bunyamin Kaya received his Bachelors degree in

Electricity Teaching from the Kocaeli University,
Kocaeli, Turkey in 2008. He was accepted Master
degree that was Interdisciplinary Studies
at
Cambridge College, Boston, MA, ABD in2010. But
he was suspend study and had to return to Turkey
due to family reasons. He has spent over 2 years
overseas experience. He joined at R&D Center,
where has been working on various research and
development projects related to flexible automotion
technologies in Nursan Wiring Harness Com.
as Responsible R&D
Departmant in 2012. He is currently studying towards a Master degree at
Electricity Technology of School of Science from Dumlupinar University,
Kutahya, Turkey.
Burcu Demirelli received her Bachelors degree in
Industrial Engineering from Kirikkale University,
Kirikkale, Turkey in 2009. Since 2011 she has been
working R&D Method Department as Responsible of
Continuous Improvement.