info@whtechnology.in
sales@whtechnology.in

+91 9513078266
+91 9964321755

POLICIES

HR Policy

Increment Policy

Objectives:

The objective of the policy is to eliminate ambiguity and bring in standard streamlined procedure that will be realistic enforceable, practical & acceptable to all.

Increment or salary revision is Performance & Merit based increase and cannot be considered as a matter of right or entitlement by every employee. 

Eligibility Criteria:

  • Employees who have completed more than one year, are eligible for increment effective form next financial year.
  • Employees who have been issued appointment letters are eligible for increment. If management is willing, contract employees can also be given increments. 
  • The increment will be considered during April month of every year. 
  • Increments are based on performance which is evaluated by the performance evaluation committee.
  • Performance Appraisal Methodology: Self / Individual Appraisal, Review by the supervisor, Planner, HR, Head operations and Management. 
  • On an average the annual increment is 8-10% of basic salary for supervisors and below.
  • On an average the annual increment is 8-20% of basic salary for department heads and above.
  • If performance is extraordinary higher increments can also be given.
  • Annual Increments are based on: Company Profits, Company margins, Department’s contribution, Individual Contribution, Industry Trends, Indian economic trends, Suppliers and Clients feedback. Company decision is final in this regard.
  • Increment order will be issued to the employee and the same will be documented in the personal file of the employee.

Decrement Policy

Objectives: 

The objective of the policy is to bring in discipline and improve performance of individual employees.

Decrements are based on the reports of performance evaluation committee.

  • On an average the annual decrement is 8-10% of basic salary for supervisors and below
  • On an average the annual decrement is 8-20% of basic salary for department heads and above.

The decrement order will be issued to the employee and documented in the personal file of the employee. 

If an employee’s salary is decrement thrice, he/she can be terminated. Management decision is final in this regard. 

Promotion policy

Our company’s promotion policy outlines the criteria, processes, and guidelines for employee advancement, ensuring fair and transparent promotion decisions based on merit, performance, and other relevant factors. 

Purpose & Benefits:

  • Fairness and Transparency
  • Employee Motivation and Retention
  • Clarity and Consistency
  • Alignment with Company Goals
  • Documentation and Record Keeping
 

Promotion Criteria:

Performance: Evaluated by performance evaluation committee. The parameters are,

    • Skills and Qualifications
    • Experience and Tenure
  • Leadership Potential

Promotion Process:

  • Internal advertisement
  • Processing the applications 
  • Evaluation by performance evaluation committee
  • Selection and communication 
  • Outline the salary and benefits
  • Documentation

Demotion policy

A demotion occurs when an employee is reassigned to a lower position than their current role, often with a reduction in responsibilities, salary, and influence. It can be a temporary or permanent solution, and it’s sometimes used as an alternative to termination. Demotions can be involuntary (imposed by the company) or voluntary (requested by the employee). 

Demotion criteria:

  • Poor Performance 
  • Disciplinary Reasons 
  • Organizational Restructuring 
  • Inadequacy of Knowledge 
  • Unable to Cope with Change 
  • Voluntary Demotion 

Evaluation Process: Evaluation by performance evaluation committee.

Key Considerations for a Demotion Policy:

    • Fairness and Consistency
    • Transparency 
  • Communication
  • Documentation 
  • Support to the employee 

Employee termination policy:

Employee termination is simply the dismissal of an employee from employment contract by our company. This step will be taken by the company when we determine that the services of an employee are no longer needed.

Notice period is ninety days with full salary. In special cases it can be a month also.

Following parameters will be considered while termination of an employee.

  • Disobedience or will full insubordination
  • Fraud, Dishonesty, or Theft
  • Wilfully damaging employer’s property
  • Taking bribes/illegal gratifications
  • Absence without applying for leave for more than 10 days
  • Late Attendance
  • Indiscipline at the workplace (consuming alcohol, harassment fellow colleagues)
  • Negligence of work

The opinion of the leaving employee (exit interview) will be considered for the betterment of our company.  Employees with more than five years of service, gratuity is payable under the Payment of Gratuity Act, 1972.

Specific Protections for Special Cases

  • Women will not be terminated while on maternity leave. 
  • Employees will not be terminated solely based on health issues unless prolonged illness affects work ability. 
  • Senior Executives and Managerial Employees will be terminated based on their individual contracts.

Resignation rules

An employee can voluntarily leave his/her position. The policies are  

  • Notice Period: Three months
  • Contractual Obligations: Employment contract reviewed by management
  • Formal Resignation: Resignation letter has to be forwarded to HR
  • Benefits: Gratuity, EL encashment, bonuses, PF which the employee is entitled. 
  • Return of Company Property: Return all company property, such as laptops, phones, keys, etc.
  • Data: Employee must transfer all confidential company data and passwords should be removed from personal devices. 
  • Exit Interview: Exit interview will be conducted to gather feedback on the employee’s experience and identify areas for improvement of our company.

Leave Policy & Holiday Schedule 

Earned Leave (EL) 

Employees are entitled to 12 Earned Leaves (EL) per calendar year. 

EL will accrue at the rate of 1 day per month.  

Credit Schedule: 

  • January to June: 6 days 
  • July to December: 6 days 
  • A maximum of 300 ELs can be carried forward till the date of retirement. 
  • Utilization, including encashment, will be at the discretion of the company. 

Casual Leave (CL): 

  • Employees are entitled to 7 days of Casual Leave (CL) per calendar year. 
  • CL is meant for personal reasons and unforeseen emergencies. 
  • CL is not encashable and cannot be carried forward to the next year. 

Sick Leave (SL): 

  • Employees are entitled to 7 days of Sick Leave (SL) per calendar year. 
  • A doctor’s prescription is mandatory to avail Sick Leave. 
  • SL is not encashable and cannot be carried forward to the next year. 

Marriage Leave:

  • An employee who is the bride or groom shall be granted 1 day of Marriage Leave on 

              the day of their wedding. 

  • If the wedding falls on a holiday or Sunday, the employee may avail the leave on the 

             next/previous working day. 

  • This leave is applicable only once during the employee’s tenure with the company 

              and is subject to prior approval.  

National and Festival Holidays:

National Holidays (03): 

  • Republic Day – January 26 
  • Independence Day – August 15 
  • Gandhi Jayanthi – October 2 

General Festival Holidays (Total: 13 days): 

Sl.no

Holiday

1

New Year 1st January

2

Sankranthi

3

Mahashivratri

4

Ugadi

5

Ramzan  

6

Labour’s Day 1st May

7

Varalakshmi Vrata

8

Ganesh Chaturthi

9

Ayudha Pooja

10

Naraka chaturdhashi

11

Deepavali

12

Kannada Rajyotsava 1st November

13

Christmas

     

Maternity Leave: 

Female employees are entitled to avail maternity leave, for a period of six months with full salary. To apply for maternity leave in splits, a woman can avail six months leave offered under the Maternity Benefit Act either entirely before or after the delivery, or split between the pre- and post-delivery periods.  She needs to give inform the management in writing, specifying the dates of absence from work. 

Paternity Leave: 

Male employees are entitled to paternity leave for a period of one week. 

Leave Application and Approval: 

Application Process: Employees should be required to submit a leave application in advance, specifying the type of leave, the dates, and the reason for the leave.

Approval Authority: The leave application should be approved by the employee’s immediate supervisors or and then HR personnel. 

PF/EPF

Contribution Percentage:

  • Employee: Contributes 12% of their basic salary 
  • Employer: Contributes 12% of the employee’s basic salary 
  • Split as follows:

EPF: 3.67%.  and employee Pension Scheme (EPS): 8.33%. 

Best practices in our company:

  • Training programs to employees in their respective fields
  • Annual day
  • Societal commitments
  • Identification of best employer and rewards
  • Environmental commitments
  • Communication training
  • Personality development
  • Release of advance to employees in case of emergency

Design policy

 A wire harness design is created based on the geometric and electrical specifications of the machinery. Depending on the situation, they can fit into electrical boxes, be hidden behind walls, or accommodate other space restrictions. A good wire harness safeguards from the impacts of scratching and vibration, & environmental issues and it helps make the most productive usage of space accessible by packaging the wires together, so they don’t sag. 

WH design policy focuses on meeting the diverse needs of various applications such as automotive, defence, electronics, aerospace, telecom, medical and automotive, while ensuring safety, reliability, and compliance with industry standards. This involves considerations such as modular design for flexibility, robust material selection for durability, and compliance with regulations. Additionally, the design policy emphasizes cost-effective solutions, sustainability, and the use of advanced manufacturing techniques. 

Factors to be Considered while designing a wiring harness are,

Environmental factors: The wiring harness’s design is determined by several factors. However, the environment in which it is used should be given most priority. For instance, some harnesses, such as those that run close to an engine or exhaust, are subjected to extremely high temperatures. On the other hand, other harnesses may be exposed to substances like water, chemicals, oil, or dirt. Exposure to abrasion is a different environmental aspect, so the harnesses must be flexible.

Wiring harness parts: Give an exact rundown of the parts required for designing your wiring parts. In addition, guarantee your outsourcing partner has the product’s part number. That permits the accomplice to supplant parts further to develop harness quality, efficiency, and price.

Length and tolerance: Be exact with the wire sizes and lengths, and consider reasonable deviations from the required length. Cut the wires according to the length and shape required.

Utilizing colour and labels: Use different wire colours and labelling language to recognize the circuit names.

Outer jacketing: Different items have specific benefits and shortcomings and are utilized for different purposes. Before picking the material as a cover, consider the objective, advantages, downsides, and other additional factors.

Testing: While some designs only need a straightforward continuity test, others might call for the wire to pass a high-voltage test. Think about what is appropriate for your application.

 

The Advantages of a good Wire Harness design are,

  • A well-built wire harness won’t break down or need to be replaced and helps to lengthen the lifespan of your electronic gadget.
  • Assembles all wires in one location for simple monitoring, access, and upkeep.
  • It acts as a support structure when linking digital components to one another or other components.
  • Reduces the amount of wire space needed.
  • Establishes an organized, orderly working atmosphere.
  • A proper design checks whether the harness design and the electricity manufacturing process work hand-in-hand for robust protection.

 

The key aspects of the design policy are:

  1. Modular and Scalable Designs:
  • Wiring harnesses are designed with modularity in mind, allowing for easy customization and replacement of components.
  • This flexibility enables efficient manufacturing processes and adaptation to changing requirements.
  • Scalability allows for integrating evolving technologies and managing the complexity of wiring systems. 
  1. Material Selection and Durability:
  • The design policy emphasizes selecting materials that are durable and resistant to various harsh environmental conditions such as abrasion, corrosion etc.
  • This includes considering factors like temperature resistance, voltage levels, and potential hazards.
  • Coverings and protective measures, like wire loom and heat shrink tubing, are used to safeguard wires from damage. 
  1. Compliance and Safety:
  • Wiring harness design prioritizes safety and compliance with industry standards and regulations.
  • This includes adhering to regulatory standards such as ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, AS9100 REV D and IPC/WHMA-A-620.
  • Advanced insulation and grounding techniques are incorporated to ensure electrical integrity and minimize the risk of failures. 
  1. Cost-Effectiveness and Sustainability:
  • The design policy aims to optimize the cost of manufacturing wire harnesses while maintaining quality. 
  • This includes using cost-modelling tools that facilitate accurate costing and IP protection. 
  • Sustainability is considered by using eco-friendly materials, recyclable components, and energy-efficient designs. 
  1. Advanced Manufacturing Techniques:
  • The design policy embraces advanced manufacturing techniques, such as automation and robotics, to improve production efficiency. 
  • These techniques enable faster prototyping, customisation, and reduced manufacturing costs. 
  • This includes utilizing software like Siemens PLM Capital for efficient design and cost management. 
  1. Collaboration and Communication:
  • Effective collaboration among multidisciplinary teams is crucial for managing complexity.
  • This includes close coordination between design engineers, electrical systems engineers, manufacturing personnel, and suppliers.
  • Clear communication ensures alignment of requirements, resolves conflicts, and facilitates smooth integration of the wire harness

 

The various activities in the design department are,

  • Should know the drawing software thoroughly
  • Converting customer drawing into company drawing
  • Terms and conditions have to be included in company drawing
  • The notes provided in the customer drawing have to be included in company drawing
  • Provide Bill of materials and indicate all Suppliers for different parts in the company drawing
  • If there are any clarifications required on the customer drawing, response should be obtained from the customer and the same should be recorded
  • Choose appropriate materials and connectors
  • Participate in the contract review to finalise the process planning

Production Policy

A comprehensive production policy for wiring harnesses encompasses several key areas: infrastructure, raw materials, design, manufacturing process, quality control, and documentation. It also includes adherence to industry standards and regulations such as ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, AS9100 REV D and IPC/WHMA-A-620.

Steps Involved in the Manufacturing Process of the Wire Harness are,

Design: It’s crucial you first attempt to complete the design. Wire harness design is one of the most important steps involved in the manufacturing process. This step is done by design department.

Design review: As soon as the Company drawing is received with Bill of Materials, MR should arrange review meeting. Design, Production, Purchase, Store and QC members should present. All the specified parts and components will be evaluated for cost, performance, and availability.

Procuring materials: Check the availability of required materials in the store, if not facilitate the material procurement.

Inward inspection: Before the start of wire harness production, we inspect and tests the procured wires, cables, and other components from the suppliers. The supplied materials will be inspected for possible defects in them. The defective materials will be rejected and the supplier will be intimated to replace the rejected parts. The entire process will be documented.

Prototyping: The working model of a wire harness design is its prototype. We test this prototype for its use in the intended application. This prototype is inspected properly and compared with the CAD models to meet all the specifications of the drawing. Any failure means reworking the project. Ensuring the accuracy and precision at the prototype stage, saves time and cost in the mass production.

Production and assembly: After the product has been prototyped or prepared digitally, it is ready for production and assembly. Infrastructure will include Production Facility, – a dedicated space with assembly lines, workstations, and storage for materials, machinery and Equipment – machineries and equipment are required for a large number of processes such as cutting, stripping, soldering, crimping, testing and wire assembling, raw Materials – Wires, cables, connectors, and other components. Instruction sheet for every operation will be prepared.

Wire stripping: To assemble wires, insulation is stripped off to reveal the central metal conductor. Care is taken to keep the wires and the insulation undamaged, as otherwise, it can lead to safety issues. If required we use magnification lens during wire stripping to ensure a smooth, clean and safe stripping process. 

Wire crimping: It is a joining process that uses a crimping tool to deform a metal connector around a wire, creating a secure and reliable electrical connection. This process is often preferred over soldering or welding because it’s faster, more precise, and allows for easy disconnection and reconnection. In case of any error, it can lead to discontinuity of the signal. Excess crimping can damage the wire, while insufficient crimping may leave the wire loose. The manufacturing team will inspect the finished crimped wires through an inspection system to prevent defects.

Wire termination: After crimping, terminal pins are attached to the wires either through soldering or by directly inserting the wire into the terminal. As the electrical devices are becoming more compact day by day, the assembly boards become further tiny. We often use microscopes to ensure correct termination to avoid defects and damages.

Testing: Once the production is completed, each wire harness undergoes testing to check its quality.
This phase ensures that the wire harness functions as intended. The final testing procedures include continuity tests, pull tests and megohm tests. Further, some visual testing is also done using a microscope. If any adjustments need to be made, they are done at this stage only. 
 After final testing, the wire harness moves to the mass production stage. We adherence to industry standards such as ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, AS9100 REV D and IPC/WHMA-A-620 while carrying out testing. 

Documentation: We will keep the documents of following. Detailed Assembly Drawings – providing clear instructions for assembly, Wire Lists and Bill of Materials – ensuring accurate material management, testing Specifications – defining testing procedures and criteria. 

Industry Standards and Regulations:

  • ISO 9001: A quality management system for ensuring consistent quality.
  • IPC/WHMA-A-620: Standard for wire harness assembly requirements.
  • AS9100C: Quality management system for the aerospace industry.
  • Advisory Circular AC 25.1701-1: Ensuring airworthiness of aircraft wire harnesses. 

WH design policy focuses on meeting the diverse needs of various applications such as automotive, defence, electronics, aerospace, telecom, medical and automotive, while ensuring safety, reliability, and compliance with industry standards. This involves considerations such as modular design for flexibility, robust material selection for durability, and compliance with regulations. Additionally, the design policy emphasizes cost-effective solutions, sustainability, and the use of advanced manufacturing techniques. 

Factors to be Considered while designing a wiring harness are,

Environmental factors: The wiring harness’s design is determined by several factors. However, the environment in which it is used should be given most priority. For instance, some harnesses, such as those that run close to an engine or exhaust, are subjected to extremely high temperatures. On the other hand, other harnesses may be exposed to substances like water, chemicals, oil, or dirt. Exposure to abrasion is a different environmental aspect, so the harnesses must be flexible.

Wiring harness parts: Give an exact rundown of the parts required for designing your wiring parts. In addition, guarantee your outsourcing partner has the product’s part number. That permits the accomplice to supplant parts further to develop harness quality, efficiency, and price.

Length and tolerance: Be exact with the wire sizes and lengths, and consider reasonable deviations from the required length. Cut the wires according to the length and shape required.

Utilizing colour and labels: Use different wire colours and labelling language to recognize the circuit names.

Outer jacketing: Different items have specific benefits and shortcomings and are utilized for different purposes. Before picking the material as a cover, consider the objective, advantages, downsides, and other additional factors.

Testing: While some designs only need a straightforward continuity test, others might call for the wire to pass a high-voltage test. Think about what is appropriate for your application.

The Advantages of a good Wire Harness design are,

  • A well-built wire harness won’t break down or need to be replaced and helps to lengthen the lifespan of your electronic gadget.
  • Assembles all wires in one location for simple monitoring, access, and upkeep.
  • It acts as a support structure when linking digital components to one another or other components.
  • Reduces the amount of wire space needed.
  • Establishes an organized, orderly working atmosphere.
  • A proper design checks whether the harness design and the electricity manufacturing process work hand-in-hand for robust protection.

 

The key aspects of the design policy are:

  1. Modular and Scalable Designs:
  • Wiring harnesses are designed with modularity in mind, allowing for easy customization and replacement of components.
  • This flexibility enables efficient manufacturing processes and adaptation to changing requirements.
  • Scalability allows for integrating evolving technologies and managing the complexity of wiring systems. 
  1. Material Selection and Durability:
  • The design policy emphasizes selecting materials that are durable and resistant to various harsh environmental conditions such as abrasion, corrosion etc.
  • This includes considering factors like temperature resistance, voltage levels, and potential hazards.
  • Coverings and protective measures, like wire loom and heat shrink tubing, are used to safeguard wires from damage. 
  1. Compliance and Safety:
  • Wiring harness design prioritizes safety and compliance with industry standards and regulations.
  • This includes adhering to regulatory standards such as ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, AS9100 REV D and IPC/WHMA-A-620.
  • Advanced insulation and grounding techniques are incorporated to ensure electrical integrity and minimize the risk of failures. 
  1. Cost-Effectiveness and Sustainability:
  • The design policy aims to optimize the cost of manufacturing wire harnesses while maintaining quality. 
  • This includes using cost-modelling tools that facilitate accurate costing and IP protection. 
  • Sustainability is considered by using eco-friendly materials, recyclable components, and energy-efficient designs. 
  1. Advanced Manufacturing Techniques:
  • The design policy embraces advanced manufacturing techniques, such as automation and robotics, to improve production efficiency. 
  • These techniques enable faster prototyping, customisation, and reduced manufacturing costs. 
  • This includes utilizing software like Siemens PLM Capital for efficient design and cost management. 
  1. Collaboration and Communication:
  • Effective collaboration among multidisciplinary teams is crucial for managing complexity.
  • This includes close coordination between design engineers, electrical systems engineers, manufacturing personnel, and suppliers.
  • Clear communication ensures alignment of requirements, resolves conflicts, and facilitates smooth integration of the wire harness

 

The various activities in the design department are,

  • Should know the drawing software thoroughly
  • Converting customer drawing into company drawing
  • Terms and conditions have to be included in company drawing
  • The notes provided in the customer drawing have to be included in company drawing
  • Provide Bill of materials and indicate all Suppliers for different parts in the company drawing
  • If there are any clarifications required on the customer drawing, response should be obtained from the customer and the same should be recorded
  • Choose appropriate materials and connectors
  • Participate in the contract review to finalise the process planning

Quality Policy

A wiring harness quality policy ensures consistent production of reliable and safe wiring assemblies through a combination of processes, documentation, and training. It focuses on preventing defects, managing the manufacturing process, and verifying the final product as AS9100 REV D and IPC/WHMA-A-620. IPC trained operators will carryout the inspection and testing.

Key Elements of a Wiring Harness Quality Policy:

Quality Management System (QMS): Adhering to standards such AS9100 REV D and IPC/WHMA-A-620 establishes a structured framework for quality control. 

Documentation and Training: Standardized documentation, including manufacturing processes and inspection procedures, ensures consistency and provides a reference point for training. 

Inspection and Testing: Thorough inspections, including visual checks and electrical safety tests (like continuity and megohm tests), ensure the harness meets specifications. 

Defect Prevention: Design for manufacturability principles, along with incoming material inspection, aim to prevent defects from being introduced in the first place. 

Traceability: Systems that track the history of components, from raw materials to the final assembly, are crucial for identifying and managing potential problems. 

Continuous Improvement: Regular review of processes, feedback from customers, and ongoing training help to identify areas for improvement and maintain quality. 

Compliance with Standards: Adhering to industry standards like IPC/WHMA-A-620A, Class III, for wire harness assemblies, helps ensure quality and reliability. 

Electrical Safety Testing: Critical final tests, such as pull tests, continuity checks, and megohm tests, ensure the harness functions correctly and safely. 

Visual Inspection: A visual inspection under magnification helps identify defects like deformed wires, incorrect crimps, and insulation issues. 

External influences: Another quality criterion is the resistance of the cable harness to external influences. Depending on the area of application, cable harnesses have to withstand extreme temperatures, vibrations, moisture or chemical influences. Appropriate materials and protective measures, such as special insulation or sheathing, are therefore already taken into account during the development phase.

Benefits of a Strong Quality Policy:

Reduced Defects: Minimizing defects saves time and money, reduces warranty claims, and enhances customer satisfaction. 

Improved Reliability: Reliable wiring harnesses are essential for the safe and efficient operation of vehicles and other equipment. 

Increased Customer Confidence: Consistent quality builds trust and encourages repeat business. 

Enhanced Safety: By preventing electrical problems, a quality policy contributes to the safety of users and the environment. 

Cost Savings: Preventing defects and reducing rework efforts can lead to significant cost savings in the long run. 

Steps Involved in the Manufacturing Process of the Wire Harness are,

Design: It’s crucial you first attempt to complete the design. Wire harness design is one of the most important steps involved in the manufacturing process. This step is done by design department.

Design review: As soon as the Company drawing is received with Bill of Materials, MR should arrange review meeting. Design, Production, Purchase, Store and QC members should present. All the specified parts and components will be evaluated for cost, performance, and availability.

Procuring materials: Check the availability of required materials in the store, if not facilitate the material procurement.

Inward inspection: Before the start of wire harness production, we inspect and tests the procured wires, cables, and other components from the suppliers. The supplied materials will be inspected for possible defects in them. The defective materials will be rejected and the supplier will be intimated to replace the rejected parts. The entire process will be documented.

Prototyping: The working model of a wire harness design is its prototype. We test this prototype for its use in the intended application. This prototype is inspected properly and compared with the CAD models to meet all the specifications of the drawing. Any failure means reworking the project. Ensuring the accuracy and precision at the prototype stage, saves time and cost in the mass production.

Production and assembly: After the product has been prototyped or prepared digitally, it is ready for production and assembly. Infrastructure will include Production Facility, – a dedicated space with assembly lines, workstations, and storage for materials, machinery and Equipment – machineries and equipment are required for a large number of processes such as cutting, stripping, soldering, crimping, testing and wire assembling, raw Materials – Wires, cables, connectors, and other components. Instruction sheet for every operation will be prepared.

Wire stripping: To assemble wires, insulation is stripped off to reveal the central metal conductor. Care is taken to keep the wires and the insulation undamaged, as otherwise, it can lead to safety issues. If required we use magnification lens during wire stripping to ensure a smooth, clean and safe stripping process. 

Wire crimping: It is a joining process that uses a crimping tool to deform a metal connector around a wire, creating a secure and reliable electrical connection. This process is often preferred over soldering or welding because it’s faster, more precise, and allows for easy disconnection and reconnection. In case of any error, it can lead to discontinuity of the signal. Excess crimping can damage the wire, while insufficient crimping may leave the wire loose. The manufacturing team will inspect the finished crimped wires through an inspection system to prevent defects.

Wire termination: After crimping, terminal pins are attached to the wires either through soldering or by directly inserting the wire into the terminal. As the electrical devices are becoming more compact day by day, the assembly boards become further tiny. We often use microscopes to ensure correct termination to avoid defects and damages.

Testing: Once the production is completed, each wire harness undergoes testing to check its quality.
This phase ensures that the wire harness functions as intended. The final testing procedures include continuity tests, pull tests and megohm tests. Further, some visual testing is also done using a microscope. If any adjustments need to be made, they are done at this stage only. 
 After final testing, the wire harness moves to the mass production stage. We adherence to industry standards such as ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, AS9100 REV D and IPC/WHMA-A-620 while carrying out testing. 

Documentation: We will keep the documents of following. Detailed Assembly Drawings – providing clear instructions for assembly, Wire Lists and Bill of Materials – ensuring accurate material management, testing Specifications – defining testing procedures and criteria. 

Industry Standards and Regulations:

  • ISO 9001: A quality management system for ensuring consistent quality.
  • IPC/WHMA-A-620: Standard for wire harness assembly requirements.
  • AS9100C: Quality management system for the aerospace industry.
  • Advisory Circular AC 25.1701-1: Ensuring airworthiness of aircraft wire harnesses. 

WH design policy focuses on meeting the diverse needs of various applications such as automotive, defence, electronics, aerospace, telecom, medical and automotive, while ensuring safety, reliability, and compliance with industry standards. This involves considerations such as modular design for flexibility, robust material selection for durability, and compliance with regulations. Additionally, the design policy emphasizes cost-effective solutions, sustainability, and the use of advanced manufacturing techniques. 

Factors to be Considered while designing a wiring harness are,

Environmental factors: The wiring harness’s design is determined by several factors. However, the environment in which it is used should be given most priority. For instance, some harnesses, such as those that run close to an engine or exhaust, are subjected to extremely high temperatures. On the other hand, other harnesses may be exposed to substances like water, chemicals, oil, or dirt. Exposure to abrasion is a different environmental aspect, so the harnesses must be flexible.

Wiring harness parts: Give an exact rundown of the parts required for designing your wiring parts. In addition, guarantee your outsourcing partner has the product’s part number. That permits the accomplice to supplant parts further to develop harness quality, efficiency, and price.

Length and tolerance: Be exact with the wire sizes and lengths, and consider reasonable deviations from the required length. Cut the wires according to the length and shape required.

Utilizing colour and labels: Use different wire colours and labelling language to recognize the circuit names.

Outer jacketing: Different items have specific benefits and shortcomings and are utilized for different purposes. Before picking the material as a cover, consider the objective, advantages, downsides, and other additional factors.

Testing: While some designs only need a straightforward continuity test, others might call for the wire to pass a high-voltage test. Think about what is appropriate for your application.

The Advantages of a good Wire Harness design are,

  • A well-built wire harness won’t break down or need to be replaced and helps to lengthen the lifespan of your electronic gadget.
  • Assembles all wires in one location for simple monitoring, access, and upkeep.
  • It acts as a support structure when linking digital components to one another or other components.
  • Reduces the amount of wire space needed.
  • Establishes an organized, orderly working atmosphere.
  • A proper design checks whether the harness design and the electricity manufacturing process work hand-in-hand for robust protection.

 

The key aspects of the design policy are:

  1. Modular and Scalable Designs:
  • Wiring harnesses are designed with modularity in mind, allowing for easy customization and replacement of components.
  • This flexibility enables efficient manufacturing processes and adaptation to changing requirements.
  • Scalability allows for integrating evolving technologies and managing the complexity of wiring systems. 
  1. Material Selection and Durability:
  • The design policy emphasizes selecting materials that are durable and resistant to various harsh environmental conditions such as abrasion, corrosion etc.
  • This includes considering factors like temperature resistance, voltage levels, and potential hazards.
  • Coverings and protective measures, like wire loom and heat shrink tubing, are used to safeguard wires from damage. 
  1. Compliance and Safety:
  • Wiring harness design prioritizes safety and compliance with industry standards and regulations.
  • This includes adhering to regulatory standards such as ISO 9001:2015, ISO 14001:2015, ISO 45001:2018, AS9100 REV D and IPC/WHMA-A-620.
  • Advanced insulation and grounding techniques are incorporated to ensure electrical integrity and minimize the risk of failures. 
  1. Cost-Effectiveness and Sustainability:
  • The design policy aims to optimize the cost of manufacturing wire harnesses while maintaining quality. 
  • This includes using cost-modelling tools that facilitate accurate costing and IP protection. 
  • Sustainability is considered by using eco-friendly materials, recyclable components, and energy-efficient designs. 
  1. Advanced Manufacturing Techniques:
  • The design policy embraces advanced manufacturing techniques, such as automation and robotics, to improve production efficiency. 
  • These techniques enable faster prototyping, customisation, and reduced manufacturing costs. 
  • This includes utilizing software like Siemens PLM Capital for efficient design and cost management. 
  1. Collaboration and Communication:
  • Effective collaboration among multidisciplinary teams is crucial for managing complexity.
  • This includes close coordination between design engineers, electrical systems engineers, manufacturing personnel, and suppliers.
  • Clear communication ensures alignment of requirements, resolves conflicts, and facilitates smooth integration of the wire harness

 

The various activities in the design department are,

  • Should know the drawing software thoroughly
  • Converting customer drawing into company drawing
  • Terms and conditions have to be included in company drawing
  • The notes provided in the customer drawing have to be included in company drawing
  • Provide Bill of materials and indicate all Suppliers for different parts in the company drawing
  • If there are any clarifications required on the customer drawing, response should be obtained from the customer and the same should be recorded
  • Choose appropriate materials and connectors
  • Participate in the contract review to finalise the process planning

Store policy

A store policy for wiring harnesses should outline procedures for handling, storage, and potentially repair, focusing on safety, quality, and compliance. This includes ensuring proper routing and packaging to prevent damage, adhering to industry standards, and providing guidance on choosing the right harness for the application. 

Key Elements of a Store Policy for Wiring Harnesses

Storage and Handling:

    • All wiring harnesses should be stored in a clean, dry environment with controlled temperature and humidity. Harnesses should be packaged in protective sleeves or boxes to prevent damage.
    • Proper Packaging: Store harnesses in appropriate packaging to protect them from damage, moisture, and contamination, especially during shipping. 
    • Environmental Controls: Maintain a controlled environment (temperature, humidity) to prevent degradation of materials and ensure product integrity. 
  • Safe Handling Practices: Train staff on proper handling techniques to avoid damage to wires, connectors, or shielding during storage and assembly. 
  • Selection and Application: Provide guidance on selecting the right harness for the intended application, considering factors like voltage, current, temperature, and environmental conditions. 
  • Compatibility: Ensure harnesses are compatible with other components in the system to avoid issues during installation or operation. 
  • Compliance: Adhere to relevant industry standards and regulations, such as UL, ISO, and IPC/WHMA-A-620, to ensure safety and performance. 
    • Repair and Maintenance: Damage Identification: Train staff on how to identify common wiring harness issues, such as damaged wires, loose connections, or corrosion. 
  • Repair Procedures: Provide clear procedures for repairing damaged harnesses, including proper crimping, soldering, and shielding techniques. 
  • Replacement: Establish criteria for replacing harnesses that are beyond repair or no longer meet safety or performance requirements. 
    • Quality Control: Inspection: Implement a quality control process that includes visual inspections, electrical testing, and functional testing to ensure that harnesses meet specifications. 
    • Documentation: Maintain records of all inspections, repairs, and replacements to track the history of each harness. 
  • Traceability: Consider implementing a traceability system to track the origin, manufacture, and testing of each harness. 
  • Safety:
  • Electrical Safety: Implement safety protocols to prevent electrical shocks and fires during installation and operation. 
  • Fire Safety: Ensure harnesses are made with flame-resistant materials and routed in a way that minimizes the risk of fires. 
  • Environmental Protection: Handle and dispose of harnesses and their components in an environmentally responsible manner. 

Copyright & Confidentiality Policy

© 2025 WH Technologies Pvt. Ltd. All rights reserved.

  • This website and its content, including but not limited to text, graphics, logos, icons, images, audio clips, video clips, digital downloads, data compilations, and software, are the property of WH Technologies Pvt. Ltd. or its content suppliers and are protected by copyright laws.
  • No part of this website may be reproduced, copied, modified, distributed, transmitted, displayed, published, or otherwise exploited for any commercial or public purpose without the prior written consent of WH Technologies Pvt. Ltd.
  • You may view, download, and print pages from this website for your personal, non-commercial use only, provided that you do not modify the content and that you retain all copyright and proprietary notices.
  • Unauthorized use of any materials on this website may violate copyright, trademark, and other laws and could result in civil or criminal penalties.

Get In touch

Banglore Office address

#323 Basavanapura Gottigere
B G Road Bangalore-560083 ,India

(+91) 9513078266
(+91) 9964321755

 sales@whtechnology.in info@whtechnology.in

US Sales Office address

3304 Sawtooth Ct.
Westlake Village – 91362
CA,USA

(+1) 818-917-1274

partha@whtechnology.in