Welcome To Wiring Harness Division
Overview
Wiring Harness Division is one of the leading manufacturer of broad range of Wiring Harnesses, Battery Cables, Wiring Sets, Connectors & Terminals.
Wiring Harness Division provides connective solutions to each vertical of the automotive world and Off-road Vehicles.
As a connective system provider Wiring Harness Division give its customers, a complete solution from design to sequenced delivery with an expertise in process & product management.
Manufacturing
Along with producing world class products, the manufacturing is geared towards innovation, reduction of costs & overheads to offer Value for money solutions. The company operates with five State-of-the-Art plants, at Greater Noida, Murbad (Mumbai), Kakkalur (Chennai), Pithampur (Indore) and Pune. With sound foundation for manufacturing components, applicators, assembly & circuit checking boards & moulding tools in-house, Wiring Harness Division produces harnesses to meet OEM’s requirements.
Latest technologies for product design results in shorter lead time for development.
Process design, process tool design & manufacturing gives value addition to error-proof manufacturing process.
Optimal cost component manufacturing gives Wiring Harness Division backward integration support for wiring harness manufacturing.
Special purpose & fully automatic machines, dedicated lines for each customer provides ability to handle critical operations for good Wiring Harness manufacturing.
Cutting Stripping & Crimping
- Automatic Wire Cutting, stripping and Crimping Machines with auto seal inserting
- Automatic wire cutting & stripping Machines
- Crimping presses
Crimping & Joining
- Ultrasonic Mid Joint Welding Machines
- Semi Auto Crimping & Mid Joint Crimping Machines
- Automatic Joint Taping Machines
- Various types of applicators for terminal crimping (In-house/Imported)
Assembly operations
- Conveyors for Assembly operations of Main Wiring Harness
- Dedicated fixed board lines
- Flexible lines for consumer goods. Cellular assembly setups
100% end-of-line checking for the parts we deliver is a key to provide best quality product to the customer.
On-Line Product Validation
- 100% end of line circuit checking for fitment & electrical continuity
- 100% end of line visual checking for verifying critical parameter
- Fool – proofing (Poka-Yoke) in circuit checking
Dedicated circuit checking boards with different load conditions for each customer
- Continuous Process Improvements
- On line measurement and auto correction
- CFM on semi auto machine
Online MV Drop, HV test & continuity Test
- Lean Approach
- Modular
- Compact
- SMED
- Poka-Yoke
- Kaizen
For wiring harnesses two types of testing are carried out – On Line i.e. Routine Performance and Endurance i.e. Non-Routine Tests
Online (Routine)
During production there is:
- 100% circuit checking for fitment & electrical continuity
- 100% visual checking for verifying critical parameter
Performance / Endurance (Non-Routine Tests)
These are of the following types:
- Electrical
- Mechanical
- Environmental
- Endurance
- Electrical
- Oil immersion testing
High Voltage Test
- Conductor resistance / voltage drop
- Mechanical / Optical
- Insertion / withdrawal forces of Coupler to Coupler
- Crimping dimensions / strength
- Mechanical position of joints / branches and overall dimensions (critical)
Environment Test
- Salt spray on plated parts
- Heat resistance test for wires / sleeve
- Cold resistance test for wires / sleeve
- Water proofing for connectors
Endurance
- Fold & Bend Test
- Twist Test
Digital Tensile Strength Testing Machine
A dedicated team for Harness optimisation mainly focused on the following areas:
- Value Analysis
- Continuous product improvement and cost reduction
- Electrical Architecture design and optimisation
- Electrical Distribution System (EDS) study & design
- Identification of new solutions to be proposed to the Customer based on internal EDS know-how, new harness / modules solutions
- Support Plants and other Services
- On line components data-base (used by different department & plants)
- + Product Design
-
Latest technologies for product design results in shorter lead time for development.
- + Process Tool Design & Manufacturing
-
Process design, process tool design & manufacturing gives value addition to error-proof manufacturing process.
- + Component Design & Development
-
Optimal cost component manufacturing gives Wiring Harness Division backward integration support for wiring harness manufacturing.
- + Wiring Harness Manufacturing
-
Special purpose & fully automatic machines, dedicated lines for each customer provides ability to handle critical operations for good Wiring Harness manufacturing.
Cutting Stripping & Crimping
- Automatic Wire Cutting, stripping and Crimping Machines with auto seal inserting
- Automatic wire cutting & stripping Machines
- Crimping presses
Crimping & Joining
- Ultrasonic Mid Joint Welding Machines
- Semi Auto Crimping & Mid Joint Crimping Machines
- Automatic Joint Taping Machines
- Various types of applicators for terminal crimping (In-house/Imported)
Assembly operations
- Conveyors for Assembly operations of Main Wiring Harness
- Dedicated fixed board lines
- Flexible lines for consumer goods. Cellular assembly setups
- + Product Validation & Improvement
-
100% end-of-line checking for the parts we deliver is a key to provide best quality product to the customer.
On-Line Product Validation
- 100% end of line circuit checking for fitment & electrical continuity
- 100% end of line visual checking for verifying critical parameter
- Fool – proofing (Poka-Yoke) in circuit checking
Dedicated circuit checking boards with different load conditions for each customer
- Continuous Process Improvements
- On line measurement and auto correction
- CFM on semi auto machine
Online MV Drop, HV test & continuity Test
- Lean Approach
- Modular
- Compact
- SMED
- Poka-Yoke
- Kaizen
- + Testing Facilities
-
For wiring harnesses two types of testing are carried out – On Line i.e. Routine Performance and Endurance i.e. Non-Routine Tests
Online (Routine)
During production there is:
- 100% circuit checking for fitment & electrical continuity
- 100% visual checking for verifying critical parameter
Performance / Endurance (Non-Routine Tests)
These are of the following types:
- Electrical
- Mechanical
- Environmental
- Endurance
- Electrical
- Oil immersion testing
High Voltage Test
- Conductor resistance / voltage drop
- Mechanical / Optical
- Insertion / withdrawal forces of Coupler to Coupler
- Crimping dimensions / strength
- Mechanical position of joints / branches and overall dimensions (critical)
Environment Test
- Salt spray on plated parts
- Heat resistance test for wires / sleeve
- Cold resistance test for wires / sleeve
- Water proofing for connectors
Endurance
- Fold & Bend Test
- Twist Test
Digital Tensile Strength Testing Machine
- + Value Analysis
-
A dedicated team for Harness optimisation mainly focused on the following areas:
- Value Analysis
- Continuous product improvement and cost reduction
- Electrical Architecture design and optimisation
- Electrical Distribution System (EDS) study & design
- Identification of new solutions to be proposed to the Customer based on internal EDS know-how, new harness / modules solutions
- Support Plants and other Services
- On line components data-base (used by different department & plants)
Plant Locations
Corporate Office – Component Division
Greater Noida
Haridwar
Murbad
Pune
Kakkalur
Pillaipakkam
Pithampur
