Wire harness assembler

Wire harness assemblers bind wires or cables to form wire harnesses used in electronic and electrical systems and equipment. They read electrical wiring plans and tie the wire together according to specifications, using cable ties, cable lacing, electrical conduit, and sleeves.

The following job titles also refer to wire harness assembler:

wire harness technician
cable harness fabricator
wire harness fabricator
technician in wire harnesses
fabricator of wire harnesses
fabricator of cable harnesses
cable harness assembler
assembler of cable harnesses
cable harness technician

A high school diploma is generally the minimum required to work as a wire harness assembler.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Wire harness assembler is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to wire harness assembler.

electrical cable assembler
electrical equipment assembler
control panel assembler
battery assembler
dental instrument assembler

These occupations require some skills and knowledge of wire harness assembler. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of wire harness assembler with a significant experience and/or extensive training.

electrical engineering technician
electrical equipment production supervisor
electromechanical engineering technician
instrumentation engineering technician
microsystem engineering technician

This knowledge should be acquired through learning to fulfill the role of wire harness assembler.

• Wire harnesses: Assemblies of wires or cables that are bound together by cable ties, tape, or lacing, and are able to transfer signals or electricity. Through binding the wires together, the wires are better protected against damage, are more compact, and require less time to install.
• Manufacture of electrical wire products: The assembly processes and manufacturing steps taken to fabricate insulated electrical wire and cable, made from steel, copper, or aluminium.
• Electrical wire accessories: Electrical wire and cable products and accessories, such as electrical connectors, splices, and wire insulation.
• Electrical discharge: Tthe qualities and applications of electrical discharge, including voltage and electrodes.
• Quality standards: The national and international requirements, specifications and guidelines to ensure that products, services and processes are of good quality and fit for purpose.
• Electricity: Understand the principles of electricity and electrical power circuits, as well as the associated risks.

These skills are necessary for the role of wire harness assembler.

• Apply soldering techniques: Apply and work with a variety of techniques in the process of soldering, such as soft soldering, silver soldering, induction soldering, resistance soldering, pipe soldering, mechanical and aluminium soldering.
• Organise wires: Apply wire markers and cable labels to identify and organise the wire. Use tie-wrap or cable lace to keep the wires together.
• Apply coating to electrical equipment: Prepare and apply coating, such as conformal coating, to electrical equipment and its components to protect the equipment against moisture, high temperature, and dust.
• Read assembly drawings: Read and interpret drawings listing all the parts and subassemblies of a certain product. The drawing identifies the different components and materials and provides instructions on how to assemble a product.
• Troubleshoot: Identify operating problems, decide what to do about it and report accordingly.
• Carry out measurements of parts: Operate measurement instruments to measure parts of manufactured objects. Take into consideration specifications of manufacturers to perform the measuring.
• Remove defective products: Remove defective materials from the production line.
• Seal wires: Fasten and insulate electric or communications wires or cables.
• Align components: Align and lay out components in order to put them together correctly according to blueprints and technical plans.
• Use electrical wire tools: Use tools to manipulate wire which will be used for electrical purposes, such as wire strippers, crimpers, soldering irons, torque wrenches, and heat guns.
• Cut wires: Operate machinery or use hand tools to cut wire.
• Bind wire: Bind cables or wire together using cable ties, conduit, cable lacing, sleeves, spot ties, cable clamps, or straps.
• Meet deadlines: Ensure operative processes are finished at a previously agreed-upon time.
• Strip wire: Strip the wire ends using wire strippers to ensure proper connections.
• Report defective manufacturing materials: Maintain required company records and forms in order to report any defective materials or questionable conditions of manufacturing machinery and equipment.
• Assemble wire harnesses: Build wire harness assemblies using wire harness boards.
• Fasten components: Fasten components together according to blueprints and technical plans in order to create subassemblies or finished products.
• Crimp wire: Attach the electrical connector to the wire using crimping tools. Here the connector and the wire are joined together by deforming one or both so they fit into each other. The electrical connector may connect the wire to an electrical terminal or may join two lengths of wire together.
• Ensure conformity to specifications: Ensure that the assembled products are conform to the specifications given.
• Operate soldering equipment: Use soldering equipment, such as a soldering gun, a soldering torch or a gas-powered iron, to melt and join together pieces of metal or steel.
• Interpret electrical diagrams: Read and comprehend blueprints and electrical diagrams; understand technical instructions and engineering manuals for assembling electrical equipment; understand electricity theory and electronic components.

This knowledge is sometimes, but not always, required for the role of wire harness assembler. However, mastering this knowledge allows you to have more opportunities for career development.

• Electrical equipment regulations: The national and international regulations with regards to the use and manufacture of electrical equipment on the workfloor. These regulations provide rules and guidelines on topics such as general risk management, electrical equipment manufacture, electrical equipment testing, electrical equipment installation, warning labels, and certificates.
• Electromechanics: The engineering processes that combine electrical and mechanical engineering in the application of electromechanics in devices that need electricity to create mechanical movement or devices that create electricity by mechanical movement.
• Electrical engineering: Understand electrical engineering, a field of engineering that deals with the study and application of electricity, electronics, and electromagnetism.
• Waste removal regulations: Know and understand the regulations and legal agreements governing the performance of waste removal activities.
• Switching devices: Devices that are able to open and close electrical circuits, such as disconnecting switches, interrupter switches, and circuit breakers.

These skills and competences are sometimes, but not always, required for the role of wire harness assembler. However, mastering these skills and competences allows you to have more opportunities for career development.

• Inspect quality of products: Use various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.
• Resolve equipment malfunctions: Identify, report and repair equipment damage and malfunctions; communicate with field representatives and manufacturers to obtain repair and replacement components.
• Maintain electrical equipment: Test electrical equipment for malfunctions. Take safety measures, company guidelines, and legislation concerning electrical equipment into account. Clean, repair and replace parts and connections as required.
• Oversee logistics of finished products: Ensure that the processes of packing, storage and shipment of finished products meet the requirements.
• Dispose of hazardous waste: Dispose of dangerous materials such as chemical or radioactive substances according to environmental and to health and safety regulations.
• Check for solder defects: Check the printed circuit board for solder defects and make adjustments as required.
• Use specialised tools in electric repairs: Use of a variety of specialised tools, instruments and machines, such as presses, drills and grinders; employ them to carry out repairs in a safety manner.
• Wear appropriate protective gear: Wear relevant and necessary protective gear, such as protective goggles or other eye protection, hard hats, safety gloves.
• Use wire hand tools: Be able to use wire hand tools, such as crimp tools, cable strippers, and cable cutters.
• Use wire processing machinery: Be able to use wire processing machines, such as wire cutting machines, wire crimping machines, and wire stripping machines.
• Replace defect components: Remove defective parts and replace them with functioning components.
• Clean components during assembly: Clean components before fixing them to other compounds or units of components during the assembly process.
• Repair wiring: Find faults in wires or cables by using specialised equipment and repair these faults depending on type of wiring.
• Apply technical communication skills: Explain technical details to non-technical customers, stakeholders, or any other interested parties in a clear and concise manner.
• Keep records of work progress: Maintain records of the progress of the work including time, defects, malfunctions, etc.
• Adjust manufacturing equipment: Regulate and monitor the manufacturing equipment settings and process parameters, such as its temperature and power level. Review the manufacturing process and equipment and suggest improvements.

8212 – Electrical and electronic equipment assemblers

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References

1. Wire harness assembler – ESCO