Automotive FAKRA Wire Harness Automatic Production Line

Customer Industry: Automotive electronics & wire harness manufacturing

Customer Name: A leading domestic automotive wire harness & connector manufacturer

Project Date: June 2023

Project Background

With the development of automotive wire harness products and market demand, the customer sought to further increase the level of production automation and manufacturing efficiency, while accommodating the production requirements of different products and strengthening product quality inspection and production data management.

Solution

Mijoint developed a fully automatic production and inspection line that supports mixed-model production of stepped-length and single/double-end cables, can be configured with various production modes depending on the product, including manual loading, automatic loading, single-end loading, and automatic long-wire winding.

The line integrates manufacturing and inspection processes, enabling automated inspection of wire length, dimensions, loose braid strands, crimping pressure, assembly depth.

Core Results

Boosted productivity: The automatic line achieves an output of 500 pcs/person-hour, compared to 100 pcs/hour with 15 operators on the previous manual line—representing a 75-fold increase in labor productivity.

Reduced labor input: Automated manufacturing and inspection significantly reduce labor input in the production process.

Improved product quality: The yield of the loose braid strand inspection machine reached over 99.5%, with assembly accuracy reaching ±0.03 mm.

Enhanced product compatibility: A single automatic line can accommodate diverse product types (stepped-length and single/double-end cables) and production modes.

Increased inspection coverage: Multiple inspection functions were integrated to achieve 100% product inspection.

Achieved production traceability: Production and inspection data can be recorded and traced.