Logistics processes

Initial situation and motivation

The Wire Harness is one of the largest, heaviest and most unwieldy components to be installed in an automobile. The main wiring harness, which consists of several thousand cables, connectors etc., is also difficult to handle and install due to its flexible nature. Up to now, this has only been possible by handling the wiring harness mainly manually during vehicle assembly. In the current assembly process, auxiliary carriers are used that are not optimized for automated assembly. Rather, the assembly is geared towards manual handling structures, which results in a large manual handling and logistics effort. The aim of SP 9 is to automate the handling of the Wire Harness from the moment it is delivered to the OEM. In future, the aim is to enable smooth automated provision on the assembly line, where the Wire Harness is to be brought into the vehicle and assembled using robots and machines.

Current focus of work

From a logistics perspective, SP 9 looks at the processes from the upstream removal of the wire harness from the building board, through delivery to the warehouse or pre-sequencing at the OEM, to provision at the installation site. Consequently, the field of consideration ends at the point where robots or humans grip or pick up the Wire Harness ready on the assembly line for installation in the vehicle. The first step in SP 9 is a generic segmentation of the supply chain as a basis for analyzing the automation potential. To this end, the current status is first analyzed and mapped in generic form. Here, for example, the following logistics processes are examined in detail with regard to the current status of automation, taking into account various line sets and forms of delivery:

• Discharge process of the incoming wire harnesses
• Sequencing process for assembly on the line
• Removal process of the wire harnesses from the load carriers
• Process for removing the outer packaging
• Feed to the conveyor belt at the right time

The next step is to create a target image for the automated logistics chain and derive key requirements. Based on this, a requirements matrix (actual state vs. target image) is created to derive further fields of action. Developments in the content of other IILS sub-projects will also be taken into account.

Outlook

In the further course of SP 9, various focal points will be considered. One of these points includes, for example, the development of alternative packaging concepts, taking into account new developments in relation to automated wire harness assembly in the downstream process step. In addition, transport, storage and supply processes as well as digitalization aspects across the value chain will also be discussed and examined.