# Optimization of Wiring Harness Logistics Flow
## 1 Introduction
### Our Previous Research  
The paper [1] overviews the production process, from design to production. In Figure 1, a schema of the logistics flow of a dynamic assembly line is presented to give a better view of the variety of processes carried out in harness production. The diagram highlights the logistics flow of the dynamic assembly line, providing an overall picture of how manual and automatic processes intertwine in producing wiring harnesses. The processes carried out in the \"Picking zone\" and on the assembly line are primarily manual. A mix of manual and semiautomated operations is performed in the preassembled elements production area, the ultrasonic welding area, and the test center. The only part of the process that is fully automated in current practice is represented by the fully automated crimping and twisting machines. Considering the share of manual operations within the production process, the article presented a theoretical case study to determine the main factors influencing the productivity of dynamic assembly lines in wiring harness production. The simulation carried out in the WITNESS Horizon Software highlighted the importance of equilibrating the tasks assigned to each workstation while considering the operators' dexterity level. Workstations subjected to substantial workloads necessitate the attendance of experienced operators  
Figure 1: Logistics flow of the dynamic assembly line. (with high dexterity). These workstations should be strategically positioned throughout the assembly line to optimize workflow fluidity and diminish waiting periods [1]. Another context that could benefit from a prior simulation and analysis in WITNESS Horizon Software is when the harness-maker must increase the production capacity to respond to their client's demand. However, expanding the physical space for production may only sometimes be feasible due to cost, logistical, or infrastructure constraints. Thus, the challenge is to find viable methods for augmenting the production capacity of wiring harnesses within the existing spatial confines while ensuring operational efficiency and cost-effectiveness. One approach to enhancing production capacity within the same space involves optimizing manufacturing processes. As was shown in the previous case study, this implies streamlining workflow, reducing cycle times, and eliminating non-value-added activities. Even though process optimization can support capacity increases, there are some limitations related to the ratio between the old client's demand and the new ones. If the ratio is around 0.5 or higher, capacity increase only by process optimization is unlikely to be achieved. In this case, modifying the assembly line structure and adding new workstations might be the only viable solution. The efficient utilization of available space through layout redesign can also contribute to increased production capacity. This involves reconfiguring the production floor to minimize material movement, reduce blockages, and enhance workflow efficiency. By employing advanced layout planning techniques, such as cellular manufacturing and optimized material flow, manufacturers can effectively maximize the utilization of available space while accommodating higher production volumes. In a preceding article [2], we formulated a theoretical framework outlining a storage system designed to address the distinctive requirements of component warehousing for harness manufacturers in the automotive industry. A Radio Frequency Identification (RFID) Ultra-High-Frequency (UHF) system was structured for deployment across all warehouse sections. The objective was to provide a straightforward and adaptable RFID system variant, characterized by low investment costs, suitable for integration into virtually any preexisting warehouse. Another challenge that must be addressed is recycling the scrap from wire harness manufacturing, which is a vital process in vehicle production.