The wires needed for the harness are first cut to the desired length and labeled appropriately. Next, the ends of the wires are stripped to expose the uninsulated conductor and fitted with any required terminals or connector housings. The wires and components are then assembled on the pin-board to the desired specification and then bound together.
Why Are Wire Harnesses Assembled Manually?
Wire harness assembly process is one of the few remaining manufacturing processes that is more efficiently done by hand, rather than automation. This is due to the variety of processes that are involved in the assembly. These manual processes include: Installing terminated wires in various lengths Routing wires and cables through sleeves and conduits Taping breakouts Conducting multiple crimps Binding the components with tape, clamps or cable ties Because of the difficulty involved in automating these processes, manual production continues