1.2 Wire Selection and Management

1.2.2 Insulation Types and measureEnvironmental line (measure along centerline, not straight-line).

Title block: harness PN/description, rev, sheet, units, scale, page zones, approvals, effectivity/variants.

Notes: default tolerances, inspection/test, crimp acceptance, marking conventions (19.2.6).

Mandates

Conventions:

• Useinsulation Jmaterial for jacks/receptacles ondictates the productwire's side,resistance Pto forheat, plugs/cable-side (or your house style—just be consistent).
• Show pin-1 trianglechemicals, and shell ground symbol where applicable.
• If using multicore cable, draw the outer cable and call the core ID schedule in the wire table.
  

1.2.3 BOM (everything you touch, by PN)

Include every purchased or consumed item per harness: connectors, contacts, seals, backshells, boots, heat-shrink, splices, lacing tape, braid/sleeve, clamps/grommets, labels, ferrules, markers, cable ties, adhesive, and multicore cable or discrete wire.

BOM columns (suggested):

Tips:

• Contacts are separate line items (socket vs pin).
• Backshells/seals called out by thread/angle and material (EMI 360° vs plain).
• Variant column: mark “A only,” “B only,” or “A/B.”
  

1.2.4 Wire (or Core) Table — the build recipe

This is where ambiguity dies. One row per wire (for discrete) or per core (for multicore).

Notes:

• Wire ID appears on labels/tags and in the From–To table.
  
• Std Class = strand flexibility (e.g., IEC 60228 Class 5/6).
• Cut length measured bare end to bare end (before terminals).
• Strip lengths per end; include tin/no-tin note if needed.
• Term PNs are the contact or ferrule part numbers, not just the connector body.
• For multicore, put Core 1…n (color/number) and the same end/cavity mapping.
  

1.2.5 From–To / Pin Map — what test uses

Make a table a tester tech can wire up from, without colors.abrasion.

1.2.3 Connector Family Selection

Selecting the correct connector is a system-level DFM decision based on environmental exposure, mating requirements, and mechanical durability.

• Contact Plating:Add Plating dictates contact resistance and durability. testGold limitsplating hereis ormandatory for low-voltage/low-current signal integrity and high mating cycles (≥100). Tin plating is sufficient for high-current power applications and low mating cycles. Never mix tin and gold contacts in notesthe same mated pair due to corrosion risk.
• Durability (continuityMating Ω max, hipot level, insulation resistance, if applicable).

  
  

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  1.2.6 Standards, codes & naming (be consistent)

  Color abbreviations (house set)Cycles): BKThe connector must be rated for the expected number of connect/disconnect cycles over the product's life. Standard industrial connectors may be rated for 50 cycles, while high-reliability test connectors may exceed 5,000 cycles.

• Sealing and Retention: For harsh environments, IP-rated (Black)Ingress Protection) sealed connectors are mandatory to prevent moisture and dust ingress. Connectors must also feature locking or latching mechanisms to guarantee mechanical retention under vibration and shock.

• ConnectorLot callouts:Control: J1/P1Every plusreel of wire, batch of terminals, and lot of connectors must be tracked by its CavityManufacturer's numbersLot Number. This information must be logged against the final harness Serial Number (SN) in the MES.
• Purpose: exactlyIf asa defect occurs (e.g., terminal fatigue or wire insulation degradation), traceability allows immediate quarantine and root cause analysis against the manufacturerspecific numbersraw them.material batch used, preventing widespread field failures.

• Wire IDs:Marking: W01…WnnThe orwire itself must be clearly identified with functionalpermanent printing (e.g., “V_MOTOR”).wire Picktype, onegauge, scheme.
  and

  Dimensions:supplier mm as default (state units in title block).

  Default tolerances (example—adjustcode) to policy):

  prevent
  • Cutincorrect length:gauge ±insertion during manual assembly.5 mm ≤ 500 mm; ± 1% beyond.
  • Strip length: ± 0.5 mm.
  • Label position: ± 5 mm from datum.
  • Overall harness length: ± 10 mm measured along centerline.
    

  Marking:

  Final labelChecklist: contentWire =Selection Harness PN–Rev, WO/Date, optional SN (if unit-level traceability). Orientation arrow shown on drawing.

  
  

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  1.2.7 Notes that save builds (put on the drawing)

  • Crimp acceptance: “Crimps per Mfr Spec; pull test per table ___.”
  • Shield term: “Provide 360° termination at J1 using backshell PN ___; heat-shrink boot PN ___.”
  • Heat-shrink cuts: lengths/tubing sizes before recover; color (usually BLK).
  • Lacing/Tie: “Lace with waxed polyester every 150 mm; no ties over labels.”
  • Bend radius: “No bends tighter than 6× OD unless otherwise noted.”
  • Cleanliness: “No flux or adhesive residue; wipe with IPA where applicable.”
  • Inspection/test: continuity, hipot (if required), label legibility, orientation check.
    

  
  

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  1.2.8 Variants & options (keep one drawing if you can)

  Use build tables or option flags:

  • Option columns (A/B/C) in the BOM and wire table with ✔ marks.
  • Do-not-stuff clearly stated (e.g., “Variant B: omit W05, cap J2 Cav 7”).
  • Show unique labels or color changes per variant if required by customer spec.
    

  
  

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  1.2.9 Revision control & effectivity

  • Rev letters in title block; change bars on affected zones; concise ECN note on the sheet.
  • Effectivity: “Applies from WO ##### onward” or serial range.
  • Superseded drawings watermarked OBSOLETE in the vault; floor copies purged.
    

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  1.2.10 Common traps → smallest reliable fixMandates

  TrapMandate	SymptomCriteria	FixRationale
  Current Derating	BOMWire saysgauge oneis thing,derated wirebased tableon anotherharness bundle size and ambient temperature.	WrongPrevents gauge/colorinsulation cut	Singledegradation sourceand spreadsheet;fire ECOrisk bothdue togetherto overheating in bundled harnesses.
  Connector Plating	Gold platingPin 1is flippedmandatory atfor onesignal endintegrity and high mating cycles. Tin for power and low cycles.	FieldEnsures reversals	Putstable connectorcontact detail with keyingresistance and pin-1required triangle;mating peer review the From–Todurability.
  Insulation Match	LengthSelect measuredinsulation straight-linebased on chemical exposure and ∆T range (e.g., PTFE for high heat/solvents).	BuildsProtects short	Statewire andintegrity drawagainst centerlinethe measure;operating add toleranceenvironment.
  Traceability Link	ContactEvery PNswire missingand terminal lot is linked to the final harness SN in the MES.	WrongAllows crimpsrapid used	List contacts in BOMquarantine and tool/locatorroot incause wireanalysis tableof material-related failures (IPC Class 3 mandate).
  Voltage Drop	LabelsWire driftgauge is selected to maintain the voltage drop (∆V) below the system's required tolerance (e.g., ≤ 5%).	OperatorsGuarantees guess	Putstable distancevoltage fromsupply backshellto anddistant a tolerance; photo on sheet
  Shield pigtail length unclear	EMI failure	Call 360° clamp or pigtail ≤10 mm explicitlyloads.

  
  

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  1.2.11 Pocket checklists

  Authoring

  • Assembly view with balloons; connector details with pin numbering
  • BOM complete (bodies, contacts, backshells, boots, splices, labels)
  • Wire/Core table filled (IDs, colors, gauge, cut/strip, ends, tools)
  • From–To/Pin map matches table; test limits noted
  • Notes/tolerances posted; units and measurement method clear
    

  Review

  • Peer build review: print the From–To and walk a sample connector
  • Sample pull/strip/crimp done once to validate strip lengths/tools
  • Variant flags checked; labels previewed
    

  Release

  • Rev + change bar; effectivity set; PDFs sealed
  • MES/buy lists updated from the same data (no retyping)
  • Obsolete sheets removed from floor; traveler updated
    

  
  

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  Clear, consistent documentation ties the entire build process together. By locking drawings, BOMs, and wire tables into one source of truth, manufacturers eliminate guesswork, accelerate production, and reduce the risk of costly rework.