# 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.

Page: https://ganiindustrial.com/cases/inverter-harness-industrialization · Language: en

A solar inverter is full of cable. Every harness carries power or signal between boards, modules and the enclosure, and each one has to be made to the same length, the same routing and the same crimp quality every time or it will not fit and may not last.

This programme took a harness family from drawings to a repeatable production process: routing boards, crimp tooling and process parameters, work instructions, and dedicated test fixtures. Then batch supply against the customer schedule.

Every harness is tested electrically, one hundred per cent, on the fixture built for it. Continuity and correct pin assignment are exactly the faults that survive visual inspection and fail at the customer, so a harness supplier that samples is really asking the customer to do the testing.

## Starting point

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.

Drawings and samples of the current harnesses existed; there was no test specification and no formal revision control on the harness documentation.

## What we need from you

- Harness drawings, samples and connector BOM
- Field-return summary with suspected failure modes
- Annual volume split across the inverter range
- Connector supplier qualification requirements

## Our scope

- 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

- 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


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GANI Industrial — engineering, manufacturing and lifecycle for European OEMs. Bursa, Türkiye.
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