| A. Standard Governance and Product Definition |
| Applicable workmanship standard |
10% |
The supplier demonstrates that cable and wire harness workmanship is controlled against the applicable requirements of
IPC/WHMA-A-620 Class 2, where continued performance is important but uninterrupted service is not always essential.
|
The supplier demonstrates that workmanship is controlled against
IPC/WHMA-A-620 Class 3, where continued high performance is essential and equipment downtime or failure may be unacceptable.
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Controlled workmanship specification, revision history, operator training records, internal audit reports, and purchase-order flow-down documents.
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Compare the purchase order, drawings, inspection plan, and work instructions. Confirm that the selected product class is explicitly stated rather than assumed.
|
| Drawing and revision control |
8% |
Current drawings identify wire type, conductor size, strip length, terminal, connector, cavity, branch length, labeling, and test requirements.
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The same information is controlled with tighter release discipline, documented approval, and traceable change implementation before production.
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Sample released drawing, bill of materials, engineering-change notice, revision register, and first-article approval record.
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Select one recent revision change and trace it from customer approval through material issue, production, inspection, and shipment.
|
| Class assignment and risk analysis |
7% |
The supplier can explain why the assembly is suitable for Class 2 service and identifies critical electrical, mechanical, and environmental characteristics.
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The supplier documents the higher consequence of defects and identifies characteristics requiring enhanced controls, inspection, and traceability.
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Process FMEA, control plan, critical-characteristic list, application information, and customer-approved acceptance criteria.
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Verify that the class assignment is consistent with the end-use risk, operating environment, and customer specification.
|
| B. Materials, Crimping, and Mechanical Workmanship |
| Material and component traceability |
10% |
Wire, terminals, seals, connectors, sleeves, and labels are identified by approved part number and controlled lot or batch information where required.
|
Traceability is maintained from incoming material through finished assembly, with clear segregation of nonconforming or substituted components.
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Approved-vendor list, incoming inspection records, certificates of conformity, lot labels, material issue records, and substitution-approval records.
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Trace one finished harness backward to material lots and verify that unauthorized substitutions cannot enter production.
|
| Wire preparation and conductor condition |
8% |
Strip length, conductor exposure, insulation condition, and strand integrity meet the approved drawing and applicable workmanship requirements.
|
Critical strip dimensions are controlled with documented setup verification and increased inspection where exposed conductor or insulation damage could affect reliability.
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Strip-length specification, setup checklist, first-piece approval, inspection gauges, defect samples, and operator qualification records.
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Measure samples from setup, mid-run, and end-of-run production. Check for nicked, cut, missing, or spread conductor strands.
|
| Crimp quality and process capability |
15% |
Crimp height, crimp width where specified, bellmouth, conductor brush, insulation support, terminal position, and pull performance meet approved requirements.
|
The same characteristics are controlled with stronger emphasis on validated tooling, setup lockout, periodic verification, and documented reaction plans for drift.
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Crimp-height records, pull-test results, cross-section analysis where required, applicator maintenance logs, tooling setup sheets, and capability studies.
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Witness a crimp setup, inspect cross-sections or approved samples, review pull-test frequency, and confirm calibration status of measuring equipment.
|
| Terminal and connector assembly |
10% |
Terminals are fully seated, locks are engaged, seals are correctly positioned, cavities match the drawing, and connector bodies are free from damage.
|
Terminal position, secondary locks, seals, keying, cavity occupancy, and connector retention are subject to documented 100% or risk-based controls as specified.
|
Connector loading checklist, cavity map, terminal-retention test records, visual standards, poka-yoke controls, and error-proofing verification.
|
Compare physical assemblies with the cavity map. Perform retention or pull-out checks using the approved method and sample plan.
|
| Routing, branching, and protection |
8% |
Branch lengths, bend radius, tie or clip positions, protective sleeving, conduit, grommets, and breakout locations conform to the drawing.
|
Routing controls also address vibration, abrasion, heat, fluid exposure, strain relief, and installation orientation where these factors affect continued service.
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Assembly board, form-board verification, dimensional inspection report, routing template, fixture-maintenance record, and environmental design requirements.
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Check a finished harness against the drawing at datum points and verify that protection is not loose, damaged, over-compressed, or incorrectly positioned.
|
| C. Inspection, Testing, and Reliability Controls |
| Electrical testing |
15% |
Continuity, short-circuit, miswire, and connector-to-cavity checks are performed according to the approved test program and wiring definition.
|
Electrical test coverage is supported by controlled test fixtures, verified programs, locked test parameters, and documented reaction to failures.
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Test program revision, fixture verification, tester calibration, test logs, failure records, repair authorization, and final-test acceptance criteria.
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Review test coverage against the pinout. Observe a challenge test using known open, short, and miswire conditions where permitted.
|
| Dimensional and visual inspection |
7% |
Inspection confirms key dimensions, markings, connector condition, workmanship, and packaging against the drawing and approved visual standards.
|
Critical-to-function dimensions and visual characteristics have defined sampling or 100% inspection requirements, with clear acceptance and rejection limits.
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Inspection plan, calibrated measuring tools, visual defect catalogue, inspection records, and nonconformance disposition records.
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Audit inspection records against actual samples and verify that rejected parts are physically segregated and dispositioned by authorized personnel.
|
| Calibration and measurement system control |
5% |
Measuring and test equipment used for acceptance decisions is identified, calibrated or verified at defined intervals, and protected from misuse.
|
Critical measurement systems have documented suitability, repeatability controls, and stronger evidence that test results remain reliable over time.
|
Calibration certificates, equipment register, out-of-tolerance procedure, gauge verification records, and measurement-system studies where applicable.
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Select instruments at the production line and confirm identification, due date, range, resolution, and linkage to recorded results.
|
| Process validation and reliability testing |
8% |
Validation covers the required assembly process and customer-specified environmental or mechanical tests when applicable to the product.
|
Reliability evidence is more extensive when the application requires high performance, including validation of crimping, sealing, retention, vibration, temperature, or fluid resistance as specified.
|
Validation plan, test laboratory qualification, test reports, sample identification, failure analysis, corrective actions, and approval records.
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Confirm that test conditions match the product application and that samples are traceable to the released design and manufacturing process.
|
| D. Delivery, Compliance, and Continuous Improvement |
| Nonconformance and corrective action |
5% |
Defects are recorded, contained, reviewed, and corrected using a documented process with customer notification when required.
|
The supplier demonstrates rapid containment, verified root-cause analysis, effectiveness checks, and trend monitoring for recurring or critical defects.
|
Nonconformance reports, 8D or equivalent corrective-action reports, defect Pareto charts, containment records, and effectiveness reviews.
|
Review recent cases from detection through closure and verify that corrective actions changed the relevant process control.
|
| Packaging, labeling, and shipment protection |
3% |
Harnesses are packed to prevent deformation, terminal damage, contamination, tangling, and loss of identification during normal transport.
|
Packaging protects critical features during extended logistics, storage, and handling, with documented controls for moisture, electrostatic, or environmental risks when applicable.
|
Packaging specification, shipping labels, packing-list records, drop or transport validation where required, and shipment inspection checklist.
|
Inspect packed samples and confirm that part number, revision, quantity, lot information, and handling instructions are consistent with the order.
|
| Capacity, lead time, and change management |
4% |
The supplier has documented capacity planning, production scheduling, and notification procedures for material, process, tooling, or site changes.
|
Capacity and change controls include documented contingency planning, qualification requirements, and customer approval before changes affecting critical performance.
|
Capacity plan, bottleneck analysis, business-continuity plan, change-notification procedure, alternate-tool qualification, and delivery-performance records.
|
Compare quoted capacity with actual equipment, staffing, test stations, tooling, and recent delivery performance for the intended program.
|
| Overall supplier assessment |
100% |
Approve when the supplier consistently meets the released design, applicable Class 2 requirements, inspection criteria, delivery obligations, and corrective-action expectations.
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Approve only when the supplier can demonstrate repeatable Class 3 controls, stronger traceability, validated processes, reliable testing, and effective control of high-consequence defects.
|
Completed supplier audit, sample-build report, first-article report, capability evidence, quality agreement, and approved corrective-action plan.
|
Use a weighted score together with mandatory-pass criteria for critical characteristics, electrical safety, traceability, and customer-specific requirements.
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