Patent Publication Number: US-2011076655-A1

Title: Wiring Harness Manufacturing Method and System

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefits of U.S. provisional patent application No. 61/213,051 filed on May 1, 2009, which is herein incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to a method and system for the manufacturing of wiring harnesses. 
     BACKGROUND OF THE INVENTION 
     Electricity is used everywhere. Electric power and electric signals are used by many of today&#39;s products. Electricity powers motors and devices while electric signals are used to sense and control various components. It is therefore common to have both an electric power system and an electric signal system in a single apparatus. 
     Electric power and electric signals are generally transmitted with wires from a start position to a destination position. For instance, it could be from a power source to a light, or a fan, in the case of an electric power circuit. Conversely, in the case of electric signals, a wire can be routed from a computer board to a sensor to transmit data between the sensor and the computer board. 
     Many wires are commonly required on a product to route electric power and electric signals between various components. It is therefore good practice to group the wires together such that they follow a single path. It helps to protect the wires, to more easily retrieve a particular wire when assembled on the apparatus, to reduce electromagnetic fields and to define the space required to allow passage of the wires. Such a group of wires is called a wiring harness. 
     From the main portion of the harness extends secondary branches routed to connect their associated components. The wiring harness comprises electric wires, terminals fittings attached to the ends of the electric wires and other parts such as connectors, tubes, protectors, tapes, grommets, seals and the like. 
     A protector can surround portions of the wiring harness. The protector is made, for example, of isolative synthetic resin, having a gutter-like cross-section. The protector is sized to accommodate electric wires therein, and tape is optionally wound around the protector to further secure the electric wires therein. The tape is preferably made of flexible non-conductive synthetic resin. An adhesive face is formed on one surface of the tape. The tape is wound directly around the group of electric wires or on the protector. 
     As mentioned above, the wiring harness is composed of a plurality of wires. Each wire has a unique and specific purpose and needs to be identified, cut to a proper length and installed at the right position in the wiring harness. Each wire&#39;s end refers to either a “from-position” (origin) or a “to-position” (destination). There is therefore a plurality of “from-to” positions to manage in association with the plurality of wires in the wiring harness. 
     Some products embed complex electronic devices and the number of wires can be significantly high. It quickly becomes complicated, confusing, tedious and therefore expensive to build wiring harnesses for such products. Moreover, products can evolve over time and in turn the complexity of the wiring harness. The risk of error is thus significant. 
     Therefore, a need for an improved method for manufacturing a wiring harness over the known art has been felt. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the present invention, there is provided a method for providing instructions for the manufacture of a wiring harness, comprising:
         acquiring data about the wiring harness to be manufactured, the wiring harness data including data about a plurality of wires to be assembled into the wiring harness;   grouping the wires based on their data; and   providing wire cutting instructions based on the grouping of the wires.       

     According to a further aspect of the present invention, there is provided a method for manufacturing a wiring harness, comprising:
         acquiring data about the wiring harness to be manufactured, the wiring harness data including data about a plurality of wires to be assembled into the wiring harness;   grouping the wires based on their data;   providing wire cutting instructions based on the grouping of the wires;   cutting wires in accordance with the cutting instructions; and   assembling the cut wires to form the wiring harness.       

     According to another aspect of the present invention, the methods are such that the wiring harness data includes connector data associated with at least some of the plurality of wires and further comprise the step of providing wire-connector assembly instructions. 
     According to yet another aspect of the present invention, the methods further comprise the step of optimizing the wire groupings so as to minimize setup time between changeovers in the wire cutting and wire-connector assembly instructions. 
     According to a further still aspect of the present invention, there is provided a system for providing instructions for the manufacture of a wiring harness, comprising:
         an input for acquiring data about the wiring harness to be manufactured, the wiring harness data including data about a plurality of wires to be assembled into the wiring harness;   a processing unit operatively connected to the input, the processing unit being configured so as to group the wires based on their data; and   an output operatively connected to the processing unit, the output being adapted to provide wire cutting instructions based on the grouping of the wires.       

     According to a further yet aspect of the present invention, there is provided a system for manufacturing a wiring harness, comprising:
         an input for acquiring data about the wiring harness to be manufactured, the wiring harness data including data about a plurality of wires to be assembled into the wiring harness;   a processing unit operatively connected to the input, the processing unit being so configured so as to:   group the wires based on their data; and   provide wire cutting instructions based on the grouping of the wires;   a cutting machine operatively connected to the processing unit for cutting wires in accordance with the cutting instructions.       

     According to another aspect of the present invention, the systems are such that the wiring harness data includes connector data associated with at least some of the plurality of wires and the processing unit is further configured so as to providing wire-connector assembly instructions, the second system further comprising a connector assembly machine operatively connected to the processing unit for assembling connectors onto associated wires in accordance with the connector assembly instructions. 
     According to yet another aspect of the present invention, the systems are such that the processing unit is further configured so as to optimize the wire groupings so as to minimize setup time between changeovers in the wire cutting and wire-connector assembly instructions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention will be described by way of example only with reference to the accompanying drawings, in which: 
         FIG. 1  is a schematic view of an example of a computer system that may be used with an illustrative embodiment of the present invention; 
         FIG. 2  is an example of a table listing “from” and “to” coordinates of a plurality of wires; 
         FIG. 3  is an example of a table listing devices and connectors associated with a plurality of wires; 
         FIG. 4  is an example of a computer assisted drawing illustrating a harness with its plurality of ramifications; 
         FIG. 5  is a block diagram showing an example of the basic structure of a wiring harness manufacturing system in accordance with an illustrative embodiment of the present invention; 
         FIG. 6  is a flow diagram of a general wiring harness assembly process; 
         FIG. 7  is a flow diagram of process for generating wire cutting instructions and wiring grouping that can be used with the process of  FIG. 6 ; 
         FIG. 8  is a flow diagram of a process for generating wire-connectors assembly instructions that can be used in conjunction with the process of  FIG. 7 ; 
         FIG. 9  is a flow diagram of a wiring harness adjustment process in accordance with an illustrative embodiment of the present invention; 
         FIG. 10  is a flow diagram of a wiring harness manufacturing process in accordance with an illustrative embodiment of the present invention; 
         FIG. 11  is a block diagram of an example of a system adapted to execute the wiring manufacturing process of  FIG. 10 ; 
         FIG. 12  is an example of a printout of a wiring harness table setup adapted to receive and route each wire of an exemplary wiring harness; 
         FIG. 13  is an example of an assembly list that can be provided by the process of  FIG. 10 ; 
         FIG. 14  is an example of a bill of material that can be provided by the process of  FIG. 10 ; 
         FIG. 15  is another example of a bill of material that can be provided by the process of  FIG. 10 ; 
         FIG. 16  is an example of a quality control check list that can be provided by the process of  FIG. 10 ; 
         FIG. 17  is an example of a wire quality control list that can be provided by the process of  FIG. 10 ; 
         FIG. 18  is an example of a wire cutting form that can be provided by an illustrative embodiment of the present invention; 
         FIG. 19  is an example of a wiring harness test file transcript (page 1 of 5); 
         FIG. 20  is an example of a wiring harness test file transcript (page 2 of 5); 
         FIG. 21  is an example of a wiring harness test file transcript (page 3 of 5); 
         FIG. 22  is an example of a wiring harness test file transcript (page 4 of 5); and 
         FIG. 23  is an example of a wiring harness test file transcript (page 5 of 5). 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENT(S) OF THE INVENTION 
     Generally stated, the non-limitative illustrative embodiment of the present invention provides a method and system for the manufacturing of wiring harnesses. 
     Referring to  FIG. 1 , there is shown an example of a computing system environment  100  usable for implementing the present invention. It is to be understood, however, that the present invention may be implemented using other general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be used to implement the present invention include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like. 
     An example of a system for implementing the present invention includes a general-purpose computing device in the form of a computer  110 . Components of the computer  110  generally include, but are not limited to, a processing unit  120 , a system memory  130 , and a system bus  121  that couples various system components including the system memory  130  to the processing unit  120 . The system bus  121  may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example only, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Associate (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as Mezzanine bus. 
     The computing system environment  100  comprises a computer  110  typically including a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer  110  and includes both volatile and nonvolatile media, removable and non-removable media. For example, computer readable media may include computer storage media and communication media. 
     Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, for example, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computer  110 . 
     Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics (such as, for example, voltage or current level, voltage or current pulse existence or nonexistence, voltage or current pulse width, voltage or current pulse spacing, etc.) set or changed in such a manner as to encode information in the signal. For example, communication media may include wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above are also included within the scope of computer readable media. 
     The system memory  130  includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM)  131  and random access memory (RAM)  132 . A basic input/output system  133  (BIOS), containing the basic routines that help to transfer information between elements within computer  110 , such as during start-up, is typically stored in ROM  131 . RAM  132  typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit  120 . For example,  FIG. 1  illustrates RAM  132  as containing operating system  134 , application programs  135 , other program modules  136 , and program data  137 . 
     The computer  110  may also include other removable/non-removable, volatile/nonvolatile computer storage media. For example,  FIG. 1  illustrates a hard disk drive  141  that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive  151  that reads from or writes to a removable, nonvolatile magnetic disk  152 , and an optical disk drive  155  that reads from or writes to a removable, nonvolatile optical disk  156  such as a CD-ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive  141  is typically connected to the system bus  121  through a non-removable memory interface such as interface  140 , and magnetic disk drive  151  and optical disk drive  155  are typically connected to the system bus  121  by a removable memory interface, such as interface  150 . 
     The drives and their associated computer storage media, discussed above and illustrated in  FIG. 1 , provide storage of computer readable instructions, data structures, program modules and other data for the computer  110 . In  FIG. 1 , for example, hard disk drive  141  is illustrated as storing operating system  144 , application programs  145 , other program modules  146 , and program data  147 . Note that these components can either be the same as or different from operating system  134 , application programs  135 , other program modules  136 , and program data  137 . Operating system  144 , application programs  145 , other program modules  146 , and program data  147  are given different numbers herein to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer  110  through input devices such as a keyboard  162 , pointing device  161  (commonly referred to as a mouse), and trackball or touch pad. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit  120  through a user input interface  160  that is coupled to the system bus, but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB). A monitor  191  or other type of display device is also connected to the system bus  121  via an interface, such as a video interface  190 . In addition to the monitor, computers may also include other peripheral output devices such as speakers  197  and printer  196 , which may be connected through an output peripheral interface  195 . 
     The computer  110  operates in a networked environment using logical connections to one or more remote computers, such as a remote computer  180 . The remote computer  180  may be a personal computer, a router, a network PC, a peer device or other common network node, and in any case the remote computer or computers typically include many or all of the elements described above relative to the personal computer  110 , although only a memory storage device  181  has been illustrated in  FIG. 1 . The logical connections depicted in  FIG. 1  include a local area network (LAN)  171  and a wide area network (WAN)  173 , but the computer  110  may additionally or alternatively use one or more other networking environments. Networking environments of all types are commonplace in offices, enterprise-wide computer networks, intranets and the Internet, for example Ethernet (broadband, high-speed), wireless WiFi, cable Internet, satellite connection, etc. 
     The computer  110  includes facilities for accessing the networks to which it is attachable. For example, when used in a LAN networking environment, the personal computer  110  is connected to the LAN  171  through a network interface or adapter  170 . Another node on the LAN, such as a proxy server, may be further connected to a WAN such as the Internet. When used in a WAN networking environment, the computer  110  typically includes a modem  172  or other means for establishing communications directly or indirectly over the WAN  173 , such as the Internet. The modem  172 , which may be internal or external, may be connected to the system bus  121  via the user input interface  160 , or other appropriate mechanism. In a networked environment, program modules depicted relative to the personal computer  110 , or portions thereof, may be stored in the remote memory storage device. For example,  FIG. 1  illustrates remote application programs  185  as residing on memory device  181 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used. It is not intended to limit the invention to use in a hard-wired network environment, since it may also be used in transiently connected environments, such as, for example, a wholly or partially wireless network environment interconnected wholly or partially via optical, infrared, and/or radio frequency wireless connections. 
     Herein, the invention is described with reference to acts and symbolic representations of operations that are performed by one or more computers, unless indicated otherwise. As such, it will be understood that such acts and operations, which are at times referred to as being computer-executed, include the manipulation by the processing unit of the computer of electrical signals representing data in a structured form. This manipulation transforms the data or maintains it at locations in the memory system of the computer, which reconfigures or otherwise alters the operation of the computer in a manner well understood by those skilled in the art. The data structures where data is maintained are physical locations of the memory that have particular properties defined by the format of the data. However, while the invention is being described in the foregoing context, it is not meant to be limiting as those of skill in the art will appreciate that variance of the acts and operation described hereinafter may also be implemented in hardware. 
     Referring now to  FIG. 2 , there is shown a table illustrating an example of a “From-To” list  200  of wires. The “From-To” list  200  is a table listing each wire to be included in a wiring harness. The term “From” relates to an end of the wire, while the term “To” refers to the opposite end of the same wire. Normally the “From” end is the end from which the current or the data is originating. Conversely, the “To” end is the end to which the current or the data is received. Additional information related to each wire is also included in the list  200  and will be explained later in more details. 
     Each wire is identified on two rows in the From-To list  200 . One row is related to each end of the wire. In other words, a row relates to the “From” end and the next row relates to the “To” end of the same wire. For example, the first two rows  232 ,  234  of the table  200  provide information about a single wire. As mentioned above, upper row  232  relates to a “From” end of the wire and lower row  234  relates to a “To” end of the wire. Each other following wire are similarly identified in the following rows of the table  200 . 
     The From-To list  200  includes a series of columns  202 - 230 . Each of the columns  202 - 230  is dedicated to a specific type of information about the subject wire. The information is associated with the columns as follows:
         the column in the From-To list  200  identified with reference number  202  relates to a numeral identification of the harness to which the wire belongs to;   the column in the From-To list  200  identified with reference number  204  relates to a wire number;   the column in the From-To list  200  identified with reference number  206  can be used for identifying possible changes to the connector on the subject end of the wire;   the column in the From-To list  200  identified with reference number  208  relates to the gage of the wire (the size of the wire);   the column in the From-To list  200  identified with reference number  210  relates to the exterior color of the wire;   the column in the From-To list  200  identified with reference number  212  relates to the type of wire;   the column in the From-To list  200  identified with numeral reference  214  relates to the length of the wire;   the column in the From-To list  200  identified with reference number  216  relates to optional data related to the wire;   the column in the From-To list  200  identified with reference number  218  relates to physical sections of the product on which the harness will be installed;   the column in the From-To list  200  identified with numeral reference  220  relates to the virtual address of the end of the wire;   the column in the From-To list  200  identified with reference number  222  relates to a break point on the main section of the harness at which the wire exits out of the main section of the harness to reach a specific element;   the column in the From-To list  200  identified with reference number  224  relates to an identification of the connector that will be connected on the subject end of the wire;   the column in the From-To list  200  identified with reference number  226  relates to an identification of the seal that seals the wire to the connector—if needed;   the column in the From-To list  200  identified with reference number  228  relates to an identification of a position on a multi-position connector; and   the column in the From-To list  200  identified with reference number  230  is left for additional comments in relation with the wire.       

       FIG. 3  shows a table illustrating an example of a “Break-Out” list  240 . A “Break-Out” list actually lists material associated with each wire in the harness. As mentioned above, the information provided in the Break-Out list  240  and the From-To list  200  can alternatively be combined in a single list. The From-To list  200  and the Break-Out list  240  in the realm of the present invention will be presented as separated lists without intending to limit the scope of the present invention. 
     The Break-Out list  240  is a table that includes data about connectors associated with each virtual address  256  (that corresponds to the column associated with reference number  220  of  FIG. 2 ) associated with each end of each wire. Each virtual address  256  uses one row in the Break-Out list  240 . For example, the first row identified with reference number  242  of the Break-Out list  240  identified by reference number  240  provides detailed information about virtual address SPR24A. In contrast, row  244  provides detailed information related to virtual address X2124C. Each virtual address is similarly identified in the following rows of the table in the column identified by reference number  240 . 
     The Break-Out list  240  also includes a series of columns  246 - 268 . Each of these columns  246 - 268  is dedicated to additional specific information about the connection at a predetermined virtual address  256  listed in the column identified by reference number  244 . The following information is associated with the various columns of the Break-Out list  240 :
         the column in the Break-Out list  240  identified with reference number  246  relates to a drawing number related to the harness;   the column in the Break-Out list  240  identified with reference number  248  relates to a possible revision number of the drawing of column  246 ;   the column in the Break-Out list  240  identified with reference number  250  relates to a break point on the main section of the harness at which the wire exits the main section of the harness to reach a specific element;   the column in the Break-Out list  240  identified with reference number  252  relates to a reference to an old system of correspondence;   the column in the Break-Out list  240  identified with reference number  254  relates to physical sections of the apparatus, or the product, to which the harness will be installed;   the column in the Break-Out list  240  identified with reference number  256  relates to the virtual address of the end of the wire, as mentioned above, this virtual address refers to the virtual address found on column identified with reference number  220  in  FIG. 2 ;   the column in the Break-Out list  240  identified with reference number  258  related to client reference identification;   the column in the Break-Out list  240  identified with reference number  260  relates to an identification of the connector that will be connected at the virtual address identified with reference number  256 ;   the column in the Break-Out list  240  identified with reference number  262  relates to an identification of an additional part associated to the connector—if needed;   the column in the Break-Out list  240  identified with reference number  264  relates to an identification of an additional part associated to the connector—if needed;   the column in the Break-Out list  240  identified with reference number  266  relates to an identification of an additional plug to close unused connection point in a connector—if needed; and   the column in the Break-Out list  240  identified with reference number  268  relates to an identification of a seal adapted to seal two connectors portions there together—if needed.       

     An example of a computer assisted drawing of a harness layout  280  is provided in  FIG. 4 . The harness layout  280  is a full scale drawing (1:1 ratio) of the wiring harness. It has to be noted that the pattern of the harness, as depicted in  FIG. 4 , does not represent the exact shape of the assembled wiring harness when the wiring harness is assembled with the final apparatus, but rather a schematic illustration, at scale, of the length of the wiring harness  280  and its associated harness branches. 
     The harness layout  280  defines a main body  282  and several break points  222 ,  250  leading to harness branches  284 . Each harness branch  284  begins  288  and ends  220 ,  256  at a “virtual address”. Each virtual address is a virtual location intended to help locate components of the wiring harness. It can be appreciated that the length of each harness section  286  is defined on the drawing  280  and that the length of each wire in the harness  280  can be calculated by summarizing the length of each applicable harness section  286 . For example, the length of the wire starting at point  288  and ending at point  290  is the added lengths of the three harness sections  286 . 1 ,  286 . 2 ,  286 . 3 . The calculation of the length of each wire in the wiring harness from the computer assisted drawing is performed automatically by the system. 
     Referring now to  FIG. 5 , there is shown a block diagram of an example of a basic structure of a wiring harness manufacturing system including various inputs  300 - 308 , a treatment component  320  and various outputs  330 - 354  in accordance with an illustrative embodiment of the present invention. Additional possible inputs include the data related to each wire in the harness  300 , the harness computer assisted drawing  302 , data about the harness already manufactured  304 , parts that are known by the wiring harness manufacturer and already available off the shelves  306 , and other known parts  308  that are easy to retrieve and be reordered by the buying department. 
     The treatment component  320  is adapted to manipulate the inputted data and process the data in order to produce the desired outputs. The treatment component  320  may be, for example, a computerized system adapted to carry on various mathematical and logical functions. Mathematical and logical functions are used in conjunction with the method to manipulate the inputted data. 
     There are several possible outputs produced by the treatment component  320 . Firstly, possible discrepancies among inputted data are identified  330  such that they can be corrected before the treatment component  320  provides other outputs. The user is prompted if discrepancies are found and an action is required from the user to waive the message by correcting or acknowledging each discrepancy. 
     Once there are no more data discrepancies, the treatment component  320  provides a number of elements forming the manufacturing plan of the wiring harness. Among these elements are wire cutting instructions  340  for each wire to be assembled in the harness, computer assisted drawings identifying assembly zones and associated assembly lists  342 , which are provided to physically manufacture the harness. There are also provided a bill of material  344 , a quality control list  346 , a quality control test file  348 , a DPMO quality data file  350 , a Kanban file and a list of new parts to buy  354 . 
     Turning now to  FIG. 6  through  FIG. 11 , there are shown some examples of processes in accordance with various illustrative embodiments of the present invention. 
     Firstly,  FIG. 6  shows a flow diagram of a high level process  360  starting, at block  362 , with the treatment of the wiring harness data that has been described above in respect with  FIG. 2  through  FIG. 4 . 
     At block  364 , once the treatment of the data is done, an optimization of the wiring harness data is performed. 
     Then, at block  366 , the wires are cut at their respective specifications and, at block  368 , assembled to form the wiring harness. 
     At block  370 , the manufactured wiring harness is tested and, at block  372 , inspected. 
     Referring now to  FIG. 7 , there is shown a flow diagram of a process  380  for generating wire cutting instructions and grouping wires, which starts, at block  382 , by acquiring a wiring harness From-To list  382 . 
     Then, at block  384 , each individual wire listed in the From-To list is identified and, at block  386 , possible discrepancies among the inputted data are evaluated so that corrupted data can be identified to prevent any further use of corrupted data in the process. 
     After the length of each wire listed in the From-To list is determined, block  388 , a computer assisted drawing file is provided at block  390 . The computer assisted drawing file may be, for example, an AutoCAD™ (.DWG) file. 
     Next, at block  392 , the length of each wire is calculated from the computer assisted drawing file and, at block  394 , is compared to the length of the corresponding wire from the From-To list wire. 
     Then, at block  396 , any discrepancies between the corresponding lengths of each wire is identified and corrected, when necessary, and like wires are grouped together to batch process some steps like wire cutting or assembling like connectors. 
     At block  400 , an optimizer using a sorting algorithm and a machine setup penalty calculator calculates the most efficient way to sequence the wire groupings for production. The optimizer evaluates the machine setup times required to change from one wire grouping to another and sequences the wire cutting instructions so that the setup time between changeovers is minimal, therefore lowering production times and improving production capacity. 
     In an illustrative example of the optimizer, six criteria are used to group the wires. Each criterion is associated with an assembling penalty value representing lost time during the changing of a given machine setup to another. The criteria are listed in a decreasing value order, i.e. the first criterion having the highest penalty value and the sixth criterion the lowest. 
     The six criteria are as follows:
         the first and second criteria are related to the presence of first and second sealants, respectively;   the third and fourth criteria are related to the presence of first and second connection terminals, respectively; and   the fifth and sixth criteria are related to the type of wire and its length, respectively.       

     Accordingly, the length of a wire has little impact (criterion 6) compared to the presence of sealants (criteria one and two) which involve the changing of sealants on the machine. 
     Wires are then separated into three groups, a first group with wires having two sealants, a second group with wires having one sealant and a third group with wires not having sealants. 
     For each group, wires having identical first five criteria are separated in sub-groups. Criterion six, related to the length of the wires, is used to sort the wires within each sub-group in a decreasing order. 
     The optimizer then orders the various sub-groups of each group by combining as many criteria as possible, starting from the ones having the highest penalty values and ending with the ones with the lowest penalty values. 
     The purpose of the optimizer is to determine the order of assembly of the wires having the lowest assembling penalty, which results in an optimized setup time. 
     Finally, at block  402 , wire cutting instructions are provided. 
     Turning now to  FIG. 8 , there is shown a flow diagram of process  420  for generating wire-connectors assembly instructions, which starts, at block  422 , by acquiring a harness Break-Out list containing additional information related to each wire and, at block  424 , identify each wire of the harness. 
     Connectors associated with each wire are then determined, at block  426 , and possible discrepancies among the connector data are evaluated at block  428 . 
     Then, at block  430 , a computer assisted drawing file of the wiring harness is provided and connectors associated with each wire are determined, at block  432 , from the computer assisted drawing file. 
     Next, at block  434 , connector data of each wire is determined from the computer assisted drawing file and compared to the connector data of the corresponding wire from the Break-Out list. 
     Then, at block  436 , any discrepancies between the corresponding connector data of each wire is identified and corrected, when necessary. 
     Finally, at block  438 , wire-connectors assembly instructions are provided. 
     Referring to  FIG. 9 , there is shown a flow diagram of a wiring harness adjustment process  450  in accordance with an illustrative embodiment of the present invention. 
     The process  450  starts at block  452  by acquiring a wiring harness From-To list and a wiring harness Break-Out list. 
     Then, at block  454 , parts of the current harness are compared to the parts on record from an already existing wiring harnesses that have already been manufactured to determine, at block  456 , the differences among the parts and provide, at block  458 , adjustment to the wiring harness already produced to avoid creating a completely new wiring harness when minor modifications can be performed on an already existing wiring harness. 
     Process  450  thus represents a time saving feature in cases of constantly evolving wiring harnesses to figure out differences between already existing wiring harnesses and the instant wiring harness to be manufactured. 
     Referring now to  FIG. 10 , there is shown a flow diagram of a wiring harness manufacturing process  470  in accordance with an illustrative embodiment of the present invention. 
     The process  470  starts at block  472  by acquiring wire specifications and then executing a process for generating wire cutting instructions and grouping wires, such as process  380  of  FIG. 7 , followed by, at block  474 , providing cutting instructions for each wire. 
     Then, at block  476 , connector specifications are acquired and a process for generating wire-connectors assembly instructions, such as process  420  of  FIG. 8 , is executed, following which, at block  478 , wire-connector assembly instructions are provided for each wire. 
     Next, at block  480 , connector crimping instructions are provided. 
     The process  470  further provides the following:
         at block  482 , a bill of material of the material required to manufacture the wiring harness;   at block  484 , a wiring harness assembly list;   at block  486 , a quality control check list to ensure the wires&#39; routing and the connectors installation are proper;   at block  488 , a quality control testing procedure or file for evaluating if the final routing of each wire in the harness is equivalent to the routing indicated in the harness&#39; data; and   at block  490 , a quality control default opportunity analysis which considers the number of wires and the number of possible connections in each connector.       

     The quality control default opportunity analysis gathers all the possible causes of defects found in each step of the manufacturing process of a wiring harness. For example, possible causes of defects related to the wire may be as follows: type of wire=1 defect opportunity; gage AWG of wire=1 defect opportunity; color of the wire=1 defect opportunity; length of cut wire=1 defect opportunity; length of stripped portion on the wire=2 defect opportunities; and choice of terminal on the wire=1 defect opportunity. Other defect opportunities related to the wire assembly may be as follows: choice of connector=1 defect opportunity; type of wire=1 defect opportunity; proper mechanical securing of each wire with the connector=1 defect opportunity; and risk of inserting the wire in the wrong connector having four positions=7 defect opportunities. 
     The defect per opportunity (DPO) is calculated at the end of the cycle using the following equation: 
         DPO =#defects/(#units×# DOC )   Equation 1
 
     where
         #defects is the number of defects;   #units is the number of units; and   #DOC is the number of defect opportunities on the connector.       

     Finally: Defect Per Million Opportunities (DPMO)=DPO×10 6 . 
     It is to be understood that in alternative embodiments any or all of the various lists, procedure/file, analysis and bill of process  470  may be optional. 
     Turning to  FIG. 11 , there is shown a block diagram of an example of a system  500  adapted to execute the wiring manufacturing process of  FIG. 10 . The system  500  is illustrated with two clients  501 ,  502  that are in communication with the computer  508  carrying configured to execute, in part or in whole, process  470  of  FIG. 10 , through a network  504  using, for example a VPN, or other communication means. Clients  501 ,  502  provide data about the wiring harness to the computer  508  which stores the data in a database  510  and has access to a printer  506  in order to, for example, print wiring diagrams, discrepancies reports, various assembly lists, quality control default opportunity analysis, etc. The computer  508  is also in connection with, in the present illustrative example, two wire cutting machines  512 ,  514  and two connector assembly machines  516 ,  518 . Both the cutting machines  512 ,  514  and the connector assembly machines  516 ,  518  are provided with automation capabilities using numerical controllers. Cutting instructions can be communicated from the computer  508  directly to the wire cutting machines  512 ,  514 . Similarly, wire-connector assembly instructions can be communicated from the computer  508  to the connector assembly machines  516 ,  518 . 
     It is to be understood that other system configurations are possible and that the number of clients, wire cutting machines and connector assembly machines may vary, and that further equipment may be added. 
     Referring now to  FIG. 12 , there is shown a printout of a wiring harness table setup adapted to receive and route each wire of an exemplary wiring harness. The printout, which is a full scale (1:1 ratio) printout, is adapted to fit on the mounting table  548  and presents a first wiring harness  550  thereon. The harness  550  has a first end  552  that leads to a first junction  554  from which extends a harness branch  556 . A second junction point  558  from which extends three additional branches is also present on the wiring harness  550  drawing. The wiring harness  550  ends with two harness ends  560 ,  562 . The connector to be mounted on each end of a wire is indicated close-by on the printout. For example, ends  560 ,  562  are illustrated nearby with their respective connectors  564 ,  566 . It can be appreciated that another wiring harness  568  is disposed next to the wiring harness  550  to maximize the space on the mounting table  548 . It can also be appreciated that the mounting table  548  is separated in sections discriminated by lines  570 . The sections are used to easily retrieve a wire or a connector on the mounting table. The sections are also associated with a portion of the product to which the manufactured wiring harness is to be mounted to provide easy correlation between the mounting table  548  and the actual product. 
     Turning now to  FIG. 13 , there is shown an example of an assembly list which may be provided at block  484  of process  470  (see  FIG. 10 ). The assembly list provides a list of connectors  580  and the quantity of each connector  582 . Then, each end of each wire  584  is listed with a number of related information such as the color of the wire  210 . The column identified by reference number  218  refers to the physical section of the product on which the harness will be installed. The column identified with reference number  228  relates to an identification of a position on a multi-position connector; and the column identified with reference number  230  is left for additional comments in relation with the wire. The column identified with reference number  260  relates to an identification of the connector to be installed on the end of the wire, if applicable, and column identified with reference number  588  indicates the position of each end of the wire on the mounting table  548  (see  FIG. 12 ) to ease retrieval of the wire. The same information is provided for each wire, wire  586  being a further example. 
     Referring to  FIG. 14 , there is shown an example of a bill of material which may be provided at block  482  of process  470  (see  FIG. 10 ). In summary, there is a listing of terminals  600  and their associated quantities  602 , the terminal seals  604  and their associated quantities  606 , wire identifications  608 , wire gages  608 , wire colors  612 , total length of the wires in millimeters  614 , total length of the wires in inches  616 , internal reference numbers  618 , a listing of connectors  620  adapted to mate the terminals  600  with their associated quantities  622 , a listing of connector back shells  624  and their associated quantities  626 , a listing of connector locks  628  and their associated quantities  630 , a listing of connector cavity plugs  632  and their associated quantities  634  and a listing of connector seals  636  and their associated quantities  638 . Other specifications are provided  640 ,  642  as needed. An alternative bill of material is shown in  FIG. 15 . The information included therein is substantially similar to the information provided in the bill of material of  FIG. 14  and will not be discussed in further details. 
     Referring to  FIG. 16  and  FIG. 17 , there are shown examples of a quality control checklist and a quality control list of wires, respectively, which may be provided at block  486  of process  470  (see  FIG. 10 ). Each column of  FIG. 17  has been previously discussed above except for column  700  which refers to optional text to be written on the wire. 
     Referring now to  FIG. 18 , there is shown an example of a wire cutting form providing a number of information required or helpful at the time of cutting a wire. 
     Finally, referring to  FIG. 19  through  FIG. 23 , there is shown an example of a quality control test file, which may be provided at block  488  of process  470  (see  FIG. 10 ), for testing the assembled wiring harness to ensure each wire is properly routed in the wiring harness. 
     Although the present invention has been described by way of particular embodiments and examples thereof, it should be noted that it will be apparent to persons skilled in the art that modifications may be applied to the present particular embodiment without departing from the scope of the present invention.