Analysis of KSK Modular Production Mode of Complete Harness

The difference between the wire harness production process and the rest of the manufacturing industry is still quite large, roughly Tier-2, CV, VW, GM, MB, PSA several categories, vehicle wiring harness such as VW and JLR is using KSK modular production mode, so that Maximize the customer's different needs. This article mainly focuses on the KSK modular production model of complete vehicle wiring harness.

The vehicle wiring harness is generally divided into several stages: Sample, V-VFF, VFF, PVS, OS, and the last SOP. Flow-Chat, FMEA, and CP must be prepared for the Sample stage. Determine the size and layout of the tooling board. The most important thing in the early stage is the BOM. According to BOM's familiarity with the types of materials and the composition of complex connectors, the components of the harnesses are more categorized and classified. It is necessary to carefully check the drawing and the BOM issued by R&D, and the site where Sample performs the line phase. Verify that many parties can ensure the accuracy of the BOM.

To the V-VFF and VFF stages, there is an overall process idea for the wiring harness. It is necessary to start the layout of all the markings on the site (materials, pre-wired wires, and wire rack wires); the definition of the size of the material box; all the connector rework manuals; Material table and number and specifications of pre-installed racks; purchase of crimping dies, test modules, OGC, tooling white modules, fuse devices, camera system; application parameters (twisted lines, ultrasonics); project needs to determine whether to put sleeve crimping or wire Under ultrasound equipment. Next, the system will begin to build BOM, Routing, cutting list, KANBAN, pay attention to distinguish between semi-automatic and fully automatic, and the amount of card settings (according to each company, there are orders to pull and system pull).

After all the above preparations are in place, it is necessary to have a preliminary work instruction for PVS. The pre-installation Pre and assembly Ass work instructions are the key and difficult points in the entire wire harness production process. Because it is KSK modular production, the customer divides each function in the car into one module, analyzes and solves them, finds their internal connection and correlation, and also considers the condition of the optional package.

The division of the workload between Pre and Ass is also a difficulty. The pre-installed beat is the key to ensure the normal flow of the assembly line. When dividing the station, all the work done should be done as far as possible. If pre-installation can achieve 80% of the insertion Porosity, and facilitate Ass operation, indicating that the station division is still good, excellent craftsman can reach 85% of the jack rate. Once the pre-installation workload is reduced, the last pre-installation will be piled up, and more workload will flow to Ass, affecting the production of the next line. The assembly is divided into wiring, plug terminals and encapsulation, OGC testing, the first board is mainly based on wiring, in the case of non-interference, the same board can be inserted at the same time the terminal and the plastic; wire tie as far as possible concentrated in a few people, It is less prone to error and less time for reloading; the wire tie tail can be completed by one person. The work instructions are not completed in a single operation. After the trials in the OS phase, there are no system errors. You need to observe the actual operations on the spot and keep on reviewing. You can also find IE support to find the bottleneck station. , adjust the station in time.

At the end of the mass production SOP, everything is fully prepared. At the beginning of the hill climbing phase, an unbalanced station can also be slightly adjusted. This way each station and each station of the assembly line can be guaranteed to be in the same beat. Train employees how to read the work instructions and some precautions according to the training instructions. The assembly line is downline to the rear, followed by the electrical test, fuse mounting and bracket mounting, camera system, full inspection, packing, packing, labeling, warehousing and shipping.

In the entire wire harness production process, the process department is a link between the reception of drawings, analysis of the anatomy, work instructions and the final training of employees. Due to the different size of each harness, the technical content is different. In addition to the above process, the staffing configuration must also consider the production efficiency. It is necessary to constantly move around the site to continuously improve the process, reduce the number of rework, and maximize the realization of zero defects and lean. produce.

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