Design for Manufacture: The Questions We Ask Before Production Starts
Most engineering problems in wire harness manufacturing are detectable at the drawing review stage. We walk through the DFM checklist our team applies to every new part number.
The most expensive way to find a design problem is after production has started. The second most expensive way is at final test. The least expensive way, by a significant margin, is at the engineering review stage, before a single component has been cut.
Every new part number that enters our system receives a formal DFM review before we accept a production order. Here's what we're looking for.
Connector and terminal compatibility
We verify that specified connectors, terminals, and cable gauges are compatible: that the terminal crimp range matches the conductor cross-section, that the connector housing is rated for the operating environment, and that mating connectors are correctly called out on both sides of the assembly.
Mismatched crimp ranges are one of the most common drawing errors we encounter. They're easy to miss at the design stage and impossible to fix cleanly in production.
Environmental and routing requirements
What environment will this harness operate in? Temperature range, exposure to fluids, UV, vibration profile: these drive material selection decisions that need to be locked in before production, not adjusted after. If a drawing specifies a cable jacket material that's unsuitable for the stated operating environment, we'll flag it before we cut anything.
Test point accessibility
Can every conductor be tested at both ends? Are test points physically accessible with the connectors mated? Drawings that don't account for testability create assemblies that are difficult or impossible to fully verify, which defeats the point of testing.
Documentation completeness
We need a complete drawing package: schematic, connector pin assignments, cable schedule, and any customer-specific requirements. Incomplete documentation at review stage means we'll ask before we build, not guess during production.
If you want to walk a new design through our DFM process before committing to a production order, get in touch with our engineering team.
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Tell us about your application. Our engineering team responds within one business day with a preliminary assessment and quote.