100% Electrical Testing

100% electrical testing

Before shipment, every harness off the line is 100% checked on an electrical test bench for continuity, short circuits, mis-pinning and insulation. Test results are archived against the harness serial number; if an issue arises in the field, the production and test history of that harness is retrieved within minutes.

What we check

• Circuit continuity: Every circuit is verified conductive end to end, with no broken or partially crimped connection.
• Short-circuit check: Circuits are measured to confirm they do not touch each other or the chassis; insulation faults are caught before the harness leaves the shop.
• Pin verification: Each terminal is checked to sit in the connector cavity the schematic specifies — mis-pinning is the most common assembly error.
• Insulation resistance: Insulation is measured to hold up under high voltage and to be adequate against moisture and contamination.
• Visual and dimensional check: Branch lengths, label positions, protective conduit and clamp intervals are compared against the drawing.

The test record travels with the harness

Every harness is labelled with its own serial number and the test result is archived against it. If an issue arises in the field, the batch it was produced in, the material lot used and how it passed testing are found within minutes. That record is the only reliable way to locate the source of a recurring problem and apply a permanent fix; a process resting on memory or guesswork cannot stop the same error being built a second time.