Mentor Graphics, a leader in electronic design automation technology, recently released a research report titled "Suppliers and OEMs in the Challenges of Automotive Harness Change Management":
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In the current design environment, how to manage changes in harness design has become a major challenge because OEMs (original equipment manufacturers) do not have a standard communication method that can be used to send relevant updates to wire harness suppliers. Most rely on hand-marked notes or other written instructions on the drawings. The MCAD field has a standardized exchange digital model that can define components, and it is time to take the same solution for the wire harness field. This article will discuss the benefits of digital harness switching and some of the key change management challenges that can help.
Overview
In the process of wire harness manufacturing, OEMs have a variety of ways to pass the details of the final product that needs to be produced to the wire harness manufacturer. At the most basic level, using the Build-to-Print model, only one printed drawing is delivered here and there is enough information to implement the manufacturing process. In some cases, the printed drawing will be accompanied by a list of from-to, and may even have an MCAD model that defines the layout of the harness.
By exchanging this basic information, wire harness suppliers still need to do a lot of work to translate and interpret drawing information, and to intersperse other fragmented information into a coherent collection to facilitate the manufacture of wire harnesses.
This method is inefficient and time consuming, resulting in ever increasing wire harness manufacturing time and OEM costs. This also means that data re-entry and misinterpretation of change requests are likely to result in a large number of errors.
Build-to-Data (produced by data)
To achieve digital exchange of harness models and take the quality and efficiency of wire harness manufacturing to a new level, you need to move from Build-to-Print to Build-to-Data. Achieving this goal requires an electronic format that can describe all the details of the harness, reduce/eliminate reliance on the drawing, and accommodate all relevant information. Over the past few years, there have been multiple attempts to do this in multiple proprietary formats and standards-based formats. The format used is not really critical, but choosing a format and starting a digital exchange of the harness model is necessary.
The benefits of digital exchange
One of the most immediate benefits of digital harness switching is forcing OEMs to meet design quality requirements. OEMs will need to create digital data using modern harness design tools, which in itself will lead to better output. If the OEM follows a rigorous design process, the Design Rule Checks are qualified during the online bundle development process, which will improve the quality of the design. The better the quality of the design provided by the OEM, the less rework required will be required, as design issues can be discovered in the early stages rather than being discovered and returned after the design delivery provider. As this exchange between OEMs and suppliers matures, OEMs will have the opportunity to examine the most common design errors discovered by suppliers in their design environment, further enhancing the initial design quality.
From a vendor's perspective, when a digital harness model is received, the time and labor required to enter it into their system will be significantly reduced. Wire harness production engineers no longer need to delve into every detail of the drawing and re-enter the data, which can take a lot of time and cause errors in the entry. Digital models can be easily imported into their systems, and value-added activities related to harness manufacturing can begin immediately. This means that errors (such as OEM-specified terminals that are not suitable for a particular wire) can be flagged and returned to the OEM in a few minutes, rather than days or weeks that can be spent in the Build-to-Print process. Part part numbers that have not yet entered the supplier system can be identified and the parts procurement process can begin very quickly, thus reducing the risk of missing parts in the harness manufacturing process. Table 1 lists typical activities that wire harness manufacturers must perform.
Table 1: This is a typical activity table to be completed by the wire harness manufacturer. Light green activities previously required manual completion, now with digital interchange and modern harness design tools. Dark green activities still need to be done manually.
However, the use of modern harness design tools can bring other benefits and is not limited to initial input and validation. These tools intelligently combine production design work with suppliers and new wiring harnesses from OEMs, which means that these changes can be absorbed and understood quickly and efficiently, as well as cost calculations without sacrificing or having to redo Completed production work.
To get these benefits, of course, to overcome some challenges. The first priority is to invest in new tools and processes. Wire harness manufacturers are always under pressure on production and prices, and senior management needs to be truly committed to investing in these improvements in order to get a return on this investment.
Key change management challenges
Often, the first challenge encountered when exchanging data in a Build-to-Data environment is the component library. The supplier's parts library is usually richer because it must contain enough information to meet the needs of the actual manufacturing harness.
The key is that the supplier must be able to maintain the part number of the parts in its own parts library, and also can correspond to the part number of multiple customers and its internal numbering system. Component part number correspondence must be done automatically in order to achieve all the benefits of digital transmission and automation. This requires some effort in the management of the parts library in the early stage, but this effort will enable the customer part number of each finished harness to be quickly and error-free into a supplier part number.
Once you have established a part number mapping system and agreed on an electronic transmission format, you can begin to exchange electronic harness data and process changes. Since this activity needs to be performed once a day, the tools that complete the activity must have a variety of functions, but they must also be easy to use, generating output that allows engineers to quickly identify the problem. A change management tool with visualization and coordination of harness topology changes (such as bundles added to a branch point (Take-out) or branch points moved to another location) and detailing attribute changes is an efficient and efficient process Essential. Figure 1 illustrates how the change management tool works.
Figure 1: Mentor Graphics Capital® Change Manager displays a graphical preview of the new changes, examining each change and detailed report difference examples.
These features are important because the vendor must verify that the new harness contains only those changes that the OEM has said and understand the impact of these changes. The main challenge for such change management is to protect the work that has been done for the manufacturing process and to merge only the changes from the new design. To achieve this goal, a set of rules must be developed to guide the automation process and apply it during the change implementation process.
Once the change has been accepted and other work has been completed, it is critical to have design comparison capabilities that verify the change execution and record it. Help again with electronic transmission and modern design tools. Since the digital model is a complete description of the harness, the design comparison can accurately show which changes can be performed, and highlighting in the graph helps to understand those changes (Figure 2).
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