GANI / MANUFACTURING — WORK PACKAGE
Harness industrialization for solar inverters
Industrialization and batch supply of a cable harness family for a European inverter manufacturer, with 100% electrical test on dedicated fixtures.
PROGRAM PROFILE
- Delivery geography
- Spain
- Annual volume
- ~14,000 harnesses/year
- Batch size
- 500–1,500 per release
- Variants in scope
- 6 harness types
- Program duration
- Two years in series
- Responsibility level
- Work package
- Standards applied
- IPC/WHMA-A-620 as practice · IEC 60204-1
THE CHALLENGE
The inverter maker’s harnesses were built from assembly drawings by a workshop with no electrical test step, and field returns traced back to crimp and pinning errors. They needed a supplier who would industrialize the harness family, not just quote the drawings.
STARTING CONDITIONDrawings and samples of the current harnesses existed; there was no test specification and no formal revision control on the harness documentation.
CUSTOMER PROVIDED
- Harness drawings, samples and connector BOM
- Field-return summary with suspected failure modes
- Annual volume split across the inverter range
- Connector supplier qualification requirements
GANI OWNED
- DFM review of the harness family with consolidated documentation
- Crimp validation and process parameters per contact family
- Design and build of dedicated 100% electrical test fixtures
- Batch production with test record per harness
- Kitting and labelled delivery per inverter build order
OUTCOME
What the program delivers.
- Harness family consolidated into a controlled documentation set
- Every delivered harness backed by an electrical test record
- Recurring batch deliveries aligned to the inverter build plan
- Field-return topic closed out in the customer’s quarterly review
