SPLA-005 - PRODUCT DESIGN STANDARD - REV.

9
EEH PN: APQP Engineer: DATE:

ITEM COMPONENT REQUIREMENT DESCRIPTION RISK DESCRIPTION NA OK NOT OK ACTION RESPONSIBLE COMMENTS
If the harness has CPAs, the print needs to indicate if the CPA
1 CPA 1. Locked CPA or Unlocked CPA
must be locked or unlocked.
1. Empire incurs in unnecessary cost
Use double crimp terminals instead of splices to join
DOUBLE CRIMP associated to Additional Labor /
2 connection points when using Empire Connection Systems
TERMINALS Material / Space / Machines when
(Connectors / Terminals)
splices are used.
1. Loose Clip - It could move and be
3 FASTENER CLIPS The Clip's Fastener Size should correspond to the Bundle Size. placed at a dimension not within
tolerance.
1. Loose Clip - It could move and be
Tape should be placed underneath the clip (2 - 3 wraps MAX)
4 FASTENER CLIPS placed at a dimension not within
to prevent it from moving from its position.
tolerance.
If the harness has an overmolded grommet, ask the customer if
the wires that go into the grommet need to follow a specific 1. Incorrect Grommet's Wire
5 GROMMET
order. Add Grommet's Wire Configuration to the print if Configuration
applicable.
Heat shrink size should be determined by EEH based on the 1. Empire incurs in unnecessary cost
6 HEATSHRINK
bundle size. when a larger heat shrink is used.

1. Leaks on Harness due to incorrect

heat shrink type.
Heat shrink type should be determined by EEH based on the
7 HEATSHRINK 2. Empire incurs in unnecessary cost
harness application - sealed / non sealed.
when a sealed heat shrink is used
when it is not required.
If an ID LABEL is located over tubing, it's color should differ
8 ID LABELS 1. Missing ID LABEL
from the tubing's (contrasting color).
If an ID LABEL is located over wire, it's color should differ from
9 ID LABELS 1. Missing ID LABEL
the wire's (contrasting color).
If an ID LABEL is located over a taped section, it's color should
10 ID LABELS 1. Missing ID LABEL
differ from the taped area (contrasting color).
1. Loose ID Label - They could unstick
and be placed at a dimension not
ID Label size should be determined by EEH based on the within tolerance
11 ID LABELS
bundle size. 2. Unreadable content - If they are
wrapped around too much content
could not be visible.
45mm of untaped wire should be left between the minifit
1. Unseated terminals
connectors and the beginning of the taped area to prevent
12 MINIFIT CONNECTOR 2. Damaged terminal's tab
applying excessive pull force to the connector's terminals
3. Damaged connectors
during the taping operation.
Use clothe tape instead of electrical tape over non slit tubing
1. Unstuck Tape
13 NON SLIT TUBING to avoid the tape from moving during the assembly process -
2. Exposed Wire
the electrical tape can move due to the soft surface.

If the harness has non slit tubing, the taping area needs to be 1. Tubing not attached properly to
14 NON SLIT TUBING
30mm MIN over the tubing before taping the wires. wire
Add spot tapes over the slit tubing (every 12 inches or as
15 SLIT TUBING required) to avoid the circuits from coming out through the 1. Exposed Circuits
tubing and have exposed circuits.
Sockets in a harness need to be different colors if they have
16 SOCKETS 1. Incorrect Sockets
similar Focal Length, Lug Pattern or Bulb Key.
1. Empire incurs in unnecessary cost
Use double crimp terminals instead of splices to join associated to Additional Labor /
17 SPLICES
connection points in Empire Connection Systems. Material / Space / Machines when
splice is used.
1. Incorrect Take Out Dimension
18 SPLICES Splices should not be located at the takeouts.
2. Damaged Splice
ASTM Standard needs to be followed to assure that splices are
19 SPLICES 1. Incorrect Splicing Process
welded correctly.
20 SPLICES All wires belonging to one splice should be the same color. 1. Crossed Circuits

If a spot tape is located over tubing, it's color should differ

21 SPOT TAPE 1. Missing Spot Tape
from the tubing's (contrasting color).
If a spot tape is located over wire, it's color should differ from
22 SPOT TAPE 1. Missing Spot Tape
the wire's (contrasting color).
If a spot tape is located over a taped section, it's color should
23 SPOT TAPE 1. Missing Spot Tape
differ from the taped area (contrasting color).

If the harness has spiral taping, ask the customer if there is any
1. Part does not Fit properly due to
24 TAPE restriction on the thickness of the taped area (bundle size) -
incorrect Bundle Size.
Add to print Min and Max Dimension if applicable.

1. Defective Crimping due to

25 TERMINALS Terminals should be packed in reels, not loose. improper crimping process - manual
feed.
1. Defective Crimping due to
improper crimping process -
26 TERMINALS Plastic Terminals should not be used.
Terminals may fall off. EEH does not
have suitable dies.
If a connector is designed to use a TPA, it must be included in 1. Unseated Terminals
27 TPA
the Print and BOM. 2. USCAR Non Compliance
1. Exposed Circuits
Tubing size should be determined by EEH based on the bundle 2. Empire incurs in unnecessary cost
28 TUBING
size. when a larger tubing is used when it
is not required.
29 WIRE COLOR Avoid using same or similar wire colors in the same connector. 1. Crossed Circuits

1. Unseated Terminals
30 WIRE INSULATION Wire insulation should be able to fit in the socket's wire slots
2. Leakage
1. Unseated terminals due to wire
31 WIRE Check for excess wire (loops) in the harness.
loops getting stuck in housing

Use tape to protect wires during tubing assembly in cases 1. Damaged/Cut wires
where slit tubing is used and where the design of the tubing is 2. Water intrusion
32 TUBING
overlapped and has sharp edges causing high risk of damaged 3. Electrical failure
wires