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Do we need GOOD and BAD Wire Harness "Dummy" Samples?

Izoyd

Involved In Discussions
#1
Hi All,

I could really use some help on this one.

We have simple wire harnesses created to drawing prints to check Warranty parts. Our Warranty returns are handled through a Corporate location, not Mfg. location, and the idea is to be able analyze the parts to send only problem parts back to the Mfg. location.

We are currently in-process to create Dummy Samples, or however everyone else refers to them, to verify the wire harnesses.

What I am wondering, is do we need Good Samples AND Bad Samples to verify the wire harnesses?

We have Final/End-of-line Inspection machines that are calibrated at the start of every shift with Go (good) / No-Go (bad) Dummy Samples that are
calibrated to the drawing/intent of the "bad" sample on a 6-month basis. The final inspection machines verify that product is actually good.

So, if a "Good" Dummy Sample is created from a production part that has passed the final inspection machine using these good and bad samples to verify the part, do we really also need to create a "Bad" Dummy Sample to check too?

Shouldn't the Good Dummy Sample consequently also be determining that the wire harness is capable of detecting a bad sample since the final inspection machine is checked for that, i.e., transferring the judgment?

I hope this isn't too complicated. I would appreciate any help that you can give!

Thank you!
 
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T

tomvehoski

#3
Is this a functional check - like a continuity and/or hipot test? Or is it a visual inspection for things like crimp location, grommet seating, label location, etc? Or both?

In any case it is a good idea to have both good and bad samples. If it is functional, just miswire one to make sure that your tester is still detecting defects. It would be good to check with the equipment manufacturer for their advice.

I would also avoid the term "dummy sample". It just makes me think I don't need to take it seriously. "Boundary Sample', "Master Sample", etc. would be better IMO.
 

Chennaiite

Never-say-die
Trusted Information Resource
#4
Hi All,

I could really use some help on this one.

We have simple wire harnesses created to drawing prints to check Warranty parts. Our Warranty returns are handled through a Corporate location, not Mfg. location, and the idea is to be able analyze the parts to send only problem parts back to the Mfg. location.
I am little confused. Are you using Wiring Harness to check your Warranty returns? If so, what is the part you are actually supplying. Just for clarification.

We are currently in-process to create Dummy Samples, or however everyone else refers to them, to verify the wire harnesses.

What I am wondering, is do we need Good Samples AND Bad Samples to verify the wire harnesses?

We have Final/End-of-line Inspection machines that are calibrated at the start of every shift with Go (good) / No-Go (bad) Dummy Samples that are
calibrated to the drawing/intent of the "bad" sample on a 6-month basis. The final inspection machines verify that product is actually good.

So, if a "Good" Dummy Sample is created from a production part that has passed the final inspection machine using these good and bad samples to verify the part, do we really also need to create a "Bad" Dummy Sample to check too?

Shouldn't the Good Dummy Sample consequently also be determining that the wire harness is capable of detecting a bad sample since the final inspection machine is checked for that, i.e., transferring the judgment?

I hope this isn't too complicated. I would appreciate any help that you can give!

Thank you!
For Electrical testing, I dont think Bad Sample is needed; it is enough that you confirm the testing equipment with only Good Sample. There are n number of discontinuities and cross-connections possible in a Wiring Harness depending upon the complexity. If you want to maintain a Bad Samples, how many different type of defect samples you would go for ? It is enough to confirm the continuity and connection only with the help of a good sample which are validated periodically.
 
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