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 aren't a quality rate. It's a liability.

Our testing capability

Every LTM harness receives continuity testing before dispatch. Beyond that, additional testing is available to match the requirements of the application:

• Continuity testing confirms every conductor is connected correctly end-to-end, with no open circuits or cross-connections. This is performed on every unit.
• 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. Available on request.
• 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. Available on request.

The documentation side

Testing is only as useful as its records. Test results are documented and included in batch dispatch documentation. Your incoming inspection team can verify what was tested, when, and by whom.

Testing scope is defined by the application and the customer specification. We have the capability to test to the level your application requires.