Design and evaluation of a combined smart nail board jig system for minimizing errors and lead time in highly complex wiring harness production assembly

Abstract

In this thesis, the jig system for making smart nail boards is designed, fabricated and tested, which combines assembly guidance and in-process electrical testing at a single workstation. It's a system comprised of a wooden jig board, Panduit nail fixtures, a PC in-process test controller from WEETECH and a Microsoft Forms digital guidance interface. Design Science Research and Design Thinking were used as the Research Framework.

The results of a two-week pilot test with three operators who assemble 20 harnesses each day indicated a first pass yield from 60 to 95 percent, an average cycle time of 58 minutes per harness reduced and a rework rate reduced from 40 to 5 percent. The operators rated the product 4.6 on usability out of 5.0. System is compliant with IPC/WHMA-A-620 Class 3 to produce military harnesses.

The results validate that assembly, and testing can be integrated in one workstation, and that there is measurable improvement in quality and efficiency in the manufacture of the complex harnesses, with a low cost replicable design approach.