Why 100% Electrical Testing Matters, and Why Sampling Isn't Enough

Statistical sampling is a reasonable quality strategy for many manufacturing contexts. If you're producing commodities at very high volume and the cost of failure is low, sampling makes economic sense. Wire harnesses for precision-critical applications are not that context.

What sampling actually means

A typical AQL sampling plan at a 1.0 acceptable quality level means you're accepting a batch where up to 1% of units may be defective. That sounds small. But if you're producing 500 harnesses for an industrial automation line, that's potentially five non-conforming assemblies shipping to your customer.

In applications where a single wiring failure causes a machine halt, a warranty return, or a safety event, five defective units in a batch isn't a quality rate. It's a liability.

What we test and why

Every LTM harness undergoes three tests before it receives a pass record:

• Continuity testing confirms every conductor is connected correctly end-to-end, with no open circuits or cross-connections.
• Hi-pot (dielectric withstand) testing applies a high voltage between conductors and ground to confirm insulation integrity. This catches insulation damage that continuity testing alone won't detect.
• Pull-force testing verifies that terminal crimps and connector insertions meet the specified retention force. A crimp that passes visual inspection can still fail mechanically under vibration.

The documentation side

Testing is only as useful as its records. Every LTM test result is logged against the unit's serial number and included in the batch dispatch documentation. Your incoming inspection team can verify what was tested, when, and by whom, for every unit in every order.

That's not a differentiator. That's the minimum standard we operate to.