Design rules for the

automation of the wire harness

Development of design rules for the standardisation of the wire harness

Design rules for the automation of the wire harness

Automation-compatible wire harness design

In sub-project 1 (SP1), design guidelines are being developed that will lead to automation-compatible wire harness designs. Important indicators here are the number of different components, the complexity of the processing procedures, as well as the actual structure of the wire harness. The guide includes both rules, for which compliance can be digitally evaluated, and recommendations of a less binding nature. In principle, the current state of the art is assessed. However, it should be possible to take into account advances in machinery and equipment and adapt the design guidelines accordingly. One designated goal is to project the impact of technology decisions on the wire harness from the early concept stages.

Starting point and motivation

The manufacturing process of a wire harness goes through various disciplines from development to installation in the vehicle. The value creation itself is presented and carried out in each company in an optimised way for the respective area of impact. Maintaining an holistic view of the value chain is therefore an essential factor in enabling more efficient wire harness production. The various motivations and experiences are to be incorporated into early stages of leadership development through close coordination between the individual companies. In this way, automation obstacles, the extent of which is difficult to assess at any specific point in time, can be avoided and economic automation made possible.

Current working focuses

In addition to the development of the design guidelines, the focus of the work in SP1 also concerns their application in practice – namely a deep integration into existing processes. As a basis for DIN 72036, rules and recommendations will be formulated, illustrated and provided with target values. A core team is dealing with overarching SP contexts, as well as real use cases for the application of these design guidelines. The design guidelines are to be integrated into standard industry software systems.


SP1 aims to raise awareness of the highly automated production of wire harnesses. Accordingly, experience from production is integrated into the design and development process, thereby identifying or preventing problems at an early stage. In addition, the content of the guideline is checked for its applicability to concrete wire harnesses by means of plausibility checks. This is used to estimate which automation step can actually be achieved.