TP0 -

Objectives and challenges

The Wire Harness Standardization Initiative (SILS) pursues a clear vision: by 2035, the production of wire harnesses should be fully digital, modular and partially automated. This is not about complete automation, but about a realistic, gradual change - based on clearly defined, machine-readable information.

In future, all production-relevant information - from pin assignment and cable lengths to modular connectors - should be structured in such a way that it can be interpreted by planning systems, software tools and machines without media discontinuity. At the heart of this vision is the modular structure of the cable harnesses: Low-voltage, high-voltage, high-frequency and non-electrical sub-scopes are conceived, designed and automatically manufactured as functional modules.

Once modeled, modules can then be reused in different vehicle variants - both at data and production level. This means that process data, machine parameters or test protocols can be used multiple times, which not only increases efficiency, but also reduces complexity and improves quality.

To achieve this, DIN 72036 lays the technical foundations for:

• the digital product description of cable harnesses and components,
• the standardization of the process description,
• automated testing and traceability,
• and the systematic modularization of the wire harness architecture.

The target image of SILS is not theoretical - it arises from concrete challenges in today's practice: planning tools and production systems often speak different "languages", data structures are not standardized, interfaces have to be interpreted individually. The result: high manual effort, limited scalability, low automation capability. This heterogeneity becomes an obstacle to innovation, especially in areas with a high number of variants, such as wire harnesses.

Joint standardization work is now creating standards that help companies to master these challenges:

• Reusability and flexibility: functional modules can be used multiple times, reducing costs and speeding up planning.
• End-to-end process digitization: From design and assembly to end-of-line testing, all steps can be planned, documented and tracked digitally.
• Interfaces and integration: The standard defines common data profiles and transfer points - based on established formats such as KBL and VEC.
• Evaluation of designs: The "degree of standard conformity" (DDA) is an objective tool that makes the automation capability of a design visible at an early stage.

A central element of the target image is the modular contact carrier, which makes the automated linking of individual parts possible in the first place. Only when connectors and module boundaries are clearly defined can a Wire Harness be assembled digitally and manufactured reliably.

The standard not only provides technical specifications for this - it also promotes economic planning and strategic investment security. Companies that rely on structured, standard-compliant data and processes today create a decisive competitive advantage for tomorrow.

The target image of the SILS is open, scalable and practical. It shows how a common standard can transform the value chain - from design to tested delivery.