Lear ESD Manufacturing Guidelines

Checklist
W/H Part Number:

ECR/ CN & BPD:

Contents Page #
1) General 2
2) Connectors 3
3) Terminals 4
4) Seals 5
5) Wires 6
6) Splices 7
7) Protection 8
8) Grommets 9
9) Takeouts & retainers 10
10) Drawing Aids 11
11) PDB Design 12
12) Packaging 13

Revisions Log 14

PE Checked ME Checked

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing General Concerns

Compliance
Num ID Concern Item to Check Y N Problem Description
1 Review the Quality/ Warranty concerns on the new design - or existing designs.
2 Have you reviewed previous warranty and reliability information to remove "design
problems"

3 Do the design reflects the knowledge from DFMEA's. PFMEA. Buck reviews, Previous
vehicle builds and DVP&R?

4 Are all applicable engineering specifications clearly indicated in the print?

5 DLL-21 Are all the special manufacturing requirements (gold terminals, twisted pairs, etc)
WK clearly indicated on the print.
6 DLL-24 All sections in the harness that require special care (flatness, bundle width, etc) are
U377 clearly indicated on the print
7 DLL-27 The harness complexity is correct for all vehicles versions.
U377
8 Has the customer approved the design
9 Is the design compatible with the FMVSS (Federal Motor Safety Standards) or any
other applicable safety regulations
10 DLL-30 The harness can not get trapped by vehicle assembly operations
U377
11 Is the harness robust enough for vehicle assembly sequence
12 Have ergonomic issues been consider for harness manufacture.
13 DLL-31 There is an evidence that in vehicle packaging conforms customer requirements
U251
14 Are product performance and testing requirements available and understood.
15 Was product recyclability addressed in the product design and material selection
16 Was the customer's prohibited, restricted and reportable chemicals list addressed
during the design
17 Has the customer material reporting requirements been complete using IMDS or
equivalent
18 DLL-43 The potential healthy issues was considered for material selection (Tapes, fibers,
U377 reflective sleeves, etc)

Rev 03 03/26/2007
Design for Manufactuing Guidelines Checklist
 Action Taken

Rev 03 03/26/2007
Design for Manufactuing Guidelines Checklist
 Manufacturing Concerns with Connectors

Compliance
Num ID Concern Item to Check Y N Problem Description
1 Greased connectors should be avoided wherever possible.

2 Minimize the types of connectors - to simplify the manufacturing process. Beware of

some terminal connector combinations, where the terminals can be inserted out of
proper orientation (i.e., 90 or 180 deg out of position.
3 Avoid the use of connectors having rear or side loaded wedges - connectors with built
in secondary wedges that are located on the top and bottom are preferred.
4 Connectors should contain 17 circuits or less - more makes the assembly too complex
and costly.
5 Avoid connectors with cavities arranged in circles. Connectors with rows and columns
are easier for assembly operators.
6 Low insertion forces are preferred for assembly and/or to prevent damage to the
components during manufacturing.
7 DLL-1 Take packaging concerns into account when selecting connectors. Large or bulky
U251 connectors may be hard to package and may cause problems during assembly.

8 Use multicolored connectors in congested areas, when possible, as an aid to assembly

operators. When mismatching of connections can occur, use different polarizations or
different terminal count connectors.
9 Minimize the use of hybrid connectors with variation in the cavity size
10 Preferr the usage of conectors with secondary locks (wedges) instead conectors
without the locks
11 Use connectors and wedges designed to provide a terminal contact point for testing
purposes.
12 In connectors using plugs insure connector-plug compatibility.
13 DLL-43 In connectors using plugs insure the correct assembly of the plugs in clearly
HB understood
14 Connectors with attachments (retainers, covers) should not accept a pisspositioned
attachmend (reverse, rotated).
15 DLL-39 The position of the connector's attachment are clearly and correctly indicated in the
U377 print.
16 Covers and latches close with an audible click
17 DLL-46 The connector covers assembly and retention force are adequate for manufacturing
U377 purposses/ No excessive effort to install it and no loose cover during handling and
packaging.

Design for Manufacturing Guidelines Checklist Rev. 03 03/26/2007

 Action Taken

Design for Manufacturing Guidelines Checklist Rev. 03 03/26/2007

 Manufacturing Concerns with Terminals

Compliance
Num ID Concern Item to Check Y N Problem Description
1 With in a family of assemblies, keep the same circuit name ID for each harness part
number in the family (for example: one circuit that is used in four part numbers/ levels
of the harness family will be call with the same ID number in each part number/ level)

2 Minimize the number of terminal variations which can be easily mixed. Micro and mini
terminals on opposite ends of a wire are a particular problem.
3 Specify single and double terminations, when possible use single terminations. Double
Terminations are hard to crimp. When you try to place two wires into a single wire
terminal, the wires become less controllable in crimping operations extremes occur.
These extremes can cause no-op conditions.
4 Dip soldering operations create poor quality, due to variations in solder build-up,
wicking action in conductors, burning of insulation, and loss of flexibility in conductors
due to solder wicking.
5 DLL-40 Select terminals that comply with the specification USCAR 21 requirements
U377
6 DLL-41 Select always the most recent generation/ version of terminal design (Ej. Molex
U251 terminals)
7 DLL-2 Select terminals that fit the wire size(s) involved. Do not assume that these terminals
U251 will always fit each connector cavity exceptions exist, particularly double terminations.
Selecting terminals that fit correctly into connector cavities saves time during
manufacturing.
8 DLL-33 The application of the selected terminals is consistent with the connector supplier
U377 recomendations
9 Evaluate the use of splices versus double terminations for each application. Some
double termination constructions, with or without splices, may be more economical.

10 Avoid the use of right angle terminals which tend to tangle during wiring fabrication. In
most cases the W/H assemblers have problems feeding the terminals through
protection and their use should be avoided when possible.
11 DLL-3 Assure the availability of specifications and tolerances for all terminals
U251
12 Insure the terminal selected is recommended for the wire gauge
13 DLL-34 A particular issue is the specifying of terminals designed for single wire application
U377 using two wires. Always use single wire terminals for single wires only.
14 Wherever is possible preferr terminals with no point solder requirement

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Action Taken

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Seals

Compliance
Num ID Concern Item to Check Y N Problem Description Action Taken
1 When ever possible refrain from using grease. The manufacturing process is messy
and costly.
2 When two or more seals cover the same wire gauge size range, choose the seal that
covers the upper limit of the size range. The smaller the seal the harder it is to
assemble to the wire.
3 When ever possible an automatically applied seal should be chosen over a manually
applied seal.
4 DLL-4 Assure the appropriate terminal, seal, cavity combination.
U251

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Wires

Compliance
Num ID Concern Item to Check Y N Problem Description
1 Circuit lengths greater than 3000 mm cause handling problems in wire assembly.
2 Avoid using circuits with very similar colors in close proximity, I.e., connectors, junction
boxes, etc.
3 Avoid wire lengths shorter than 250 mm for cutting and double wire terminations 100
mm for single wire automatic terminations.
4 If two or more circuits with the same circuit number (color code) are in the same
connector they must not require polarization.
5 Avoid the use of 0.30 mm gauge wire in weld splices, since it tends to burn or break.

6 Eliminate foil tape and drain wire assemblies through other means of EMC reduction (if
possible).
7 All wire materials should be indicated as lead free in the drawing and the spec.
8 DLL-44 The wire insulation do not interfere with the circuit assembly operation/ Dimensions,
U377 insertion feasibility.
9 DLL-22 All special characteristics for wires must be indicated.
U251

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Action Taken

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Splices

Compliance
Num ID Concern Item to Check Y N Problem Description
1 Limit splices to 8 circuits. Unbalanced splices caused by large wire size differences
create problems.
2 DLL-42 There is no difference greater than 4 sizes between the smaller and biggest wires on a
U377 certain splice
3 DLL-35 The cover for each splice nugget is clearly indicated in the print.
U377
4 If 0.30 mm gauge wire is used in a splice cover the splice with dual wall heat shrink
tube. The tube adds support to the splice making it easier to handle.
5 Locate splices at least 75 mm or more from takeouts and edges of troughs. In some
cases more space is needed to place heat shrink tubing in toasters.
6 When ever possible apply splice tape instead of heat shrink tube (apply heat shrink
tube for water proofness only). Splice tape is easier to apply and less expensive.

7 Apply HST to 22 awg gauge spliced circuits to avoid broken splices.

8 No butyl/ mastic application for splice protection
9 Provide 100 mm minimum spacing between splices in a W/H if practical.
10 DLL-32 Locate splices where they will not be damaged by harness regular handling and
U251 harness packing and unpacking.
11 The drawing should show the location and reference point of the splice and the kind of
nugget protection.
12 Standardize all splice locations wherever possible.
13 The splice configuration is correct (circuit at the left/ rigth) to prevent the circuits need
to be looped back or twisted during circuit routing.
14 DLL-5 Locate splices at least 50 mm away from the center of the clip nodes.
U377
15 Make sure to add all required splice information is in the drawing
16 DLL-6 Avoid to many splices with in splices (web/ net splices). They are very difficult to
U377 handle.
17 Splice identification numbers should be the same- from one harness to another- within
each family of harnesses.
18 Avoid 1 + 1 splices
19 Avoid twisted splices

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Action Taken

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Protection

Compliance
Num ID Concern Item to Check Y N Problem Description
1 DLL-32 Minimize the number of components which are easily mixed, communize all protection
U251 lengths.
2 Standardize the sizes and lengths of convolute within a family of assemblies slit tubing
or convolute is preferred over non-slit.
3 Try to use slit tube in place of adhesive vinyl sheet. Slit tube is less expensive and
easier to apply.
4 Reduce the number of different types of tapes used on the same harness.
5 When ever possible replace acetate tape with vinyl tape. Vinyl tape is less expensive.

6 Different colored identification tapes are preferred within families of harnesses.

7 Small wire bundle sizes (10 circuits or less) are difficult to candy stripe: use spot tapes
or full wrap if possible.
8 Specify the actual lengths of protection you require on your harness, when ever
possible. Undefined lengths do not convey design wants to Manufacturing.
9 DLL-22 End or start taping 50 mm behind connectors to provide hand clearance during W/H
U251 fabrication.
10 DLL-7 Remember to take splices and shielding into consideration while calculating protection
U377 diameters.
11 When ever possible candy stripe W/H instead of full wrap taping.
12 Do not use unslit sleeving or tubing over anything except single circuits- without
manufacturing concurrence- due to assembly problems.
13 If a continuous piece of convolute contains takeouts, cutting of the insulation may occur
at the takeout points. Use of shorter pieces, joined at takeouts, can prevent the cutting.

14 Assure all the needed taping is indicated on the drawing

15 DLL-23 The taping applied on PVC tube must be sufficient to ensure the tube stays closed
U377 during harness handling and installation/ No exposed wires
16 Insure all the takeouts are protected as required by any damage during harness
installation in the vehicle.
17 Indicate reference points for tubing and taping
18 Positioning a retainer at a takeout point on a large major assembly results in an
unacceptable (no build) manufacturing process.
19 Several small shields in place of one large shield can or might improve rotary assembly
operations. Troughs (shields) with large bends or elevation changes (Drop/ rises)
create difficulties in routing, and in the retention of wires.
20 Do not tape "as close as possible" to the back of the connectors.
21 Do not apply end wrap on non slit PVC tube, when other end is secured.

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Action Taken

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Grommets

Compliance
Num ID Concern Item to Check Y N Problem Description Action Taken
1 Grommets are usually hard to apply to a W/H. When ever possible increase the
diameter at the goose neck portions to allow the W/H smoother passage through the
grommet.
2 When passing non-slit convolute through a tight fitting grommet use a thicker walled
convolute to help prevent the convolute from collapsing. Wires can than be passed
through the convolute unobstructed.
3 When designing or selecting a grommet to use, remember to account for W/H
attachment. Make sure there's enough room to tape the W/H to the grommet.
4 Be sure to review tolerances of the internal diameter, in conjuction with the tubing for
an easy manufacturability
5 Be sure all visual aids for grommet orientation are understandable
6 Dimensional point of the grommet must be clear on the drawing.
7 DLL-8 If the grommet require the usage of lubricant, be sure the lubricant part number and the
U251 part in the grommet to be applied are clearly indicarted in the drawing.
8 DLL-9 Verify the Customer plant assembly method when selecting the grommet to be used to
U377 prevent potential quality issues due to gromment handling and installation.
9 DLL-10 Insure the grommet tolerances are compatible with the seet metal tolerance
U377 (considering always size and flatness).

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Takeouts

Compliance
Num ID Concern Item to Check Y N Problem Description
1 A minimum of 100 mm is preferred between takeouts for hand taping access.
2 Standardize the major trunks , in W/H families, so that they can be built on common
jigs.
3 Numerous takeouts branching from one point can cause manufacturing problems,
especially short branches. Try to minimize the number of takeouts coming out of a
single location.
4 When ever possible, have takeouts directed away from the operator's position to
facilitate terminal insertion on W/H fixtures.
5 If you have a complex takeout (multiple branches), is there adequate room to tape to
the back of connectors?
6 Do not place clips or retainers at takeout points.
7 DLL-11 Insure the clip location does not interfere with the takeout.
U377
8 Assure all takeouts are secured with hanking tape where needed.
9 Avoid takeouts going downwards
10 No full tape when harness flexibility is needed.
11 Insure the compatibility of the clip p/n and the bundle size.
12 DLL-12 No similar clips in the same harness. Do not use clips with washers and without
U377 washers in the same harness.
13 Do not assign variable points as clip reference.
14 Standardize the orientation of retainers wherever is possible.
15 Each takeout from multiple outlets is measured from the edge of the shield- not from
some unmeasurable point within the assembly or the shield.
16 DLL-13 Avoid the takeouts to be oriented toward or away from the operator (3D design)
U377
17 The retainers are secured to the bundle and not loose position (no rotation)
18 The retainers comply with a minimum of 25 pounds of retention force to the bundle
19 DLL-38 For retainer with low value of retention there are spot tapes added to increase the
U377 retention force

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Action Taken

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Drawing Aids

Compliance
Num ID Concern Item to Check Y N Problem Description Action Taken
1 Clearly portray takeout orientations, particularly in early drawings which affects new or
reworked jigs and fixtures. Don't forget to indicate the "key" orientation of major
connectors to the W/H.
2 A datum, control point from which the W/H can be built is preferred. This datum should
correspond to a key customer functional need.
3 Insure your dimensioning system and critical characteristic designations reflect
reasonable and feasible controls by Manufacturing. Critical or tight tolerances to clips
or other components taped to convolute are a problem.
4 Flag all significant or critical characteristics with a symbol or note on all drawings where
areas of concern are located.
5 Wiring designs reflecting a "two-dimensional" assembly board are preferred.
6 Isometric views, on alpha drawings, are preferable to reflect the in-car wire positioning
as an aid to jig design.
7 Standardization of views and sections is important. Remember to include a view of
every clip used on the W/H. Orientation of clips is necessary in W/H manufacturing.

8 DLL-36 Views and sections are consistent within the print.showing the same orientation for
U377 components reflected in different sections and views.
9 Point-to-point dimensioning of clips is preferred instead of dimensioning from one point,
especially long dimensions.
10 When ever possible standardize all clips to make the manufacturing process easier.

11 Always include all necessary hanking views on the W/H drawing. The more detailed
the drawing, the easier it is for Manufacturing to package the harness.
12 "Flag" significant/ critical characteristics with a symbol or notes on all drawings where
SC/ CC have been determined
13 Special testing associated with a given connector/ terminal should be identified on the
drawing, e.g. special push tests, micro-mini terminal detection, relay.

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with PDB

Compliance
Num ID Concern Item to Check Y N Problem Description Action Taken
Terminal Design :
1 Single orientation for plugging to cassette
2 Proper insertion force into cassette
3 DLL 14 Proper retention force in cassette
U377
4 Positive locking feature -- single orientation -- guide rails to insure orientation
5 Stability----minimal bias in cavity
6 DLL-15 Contact surface area provided for circuit test and push test
U377
7 Minimal over-travel to seat (common tolerance with cassette cavity and lock feature)
8 Maximum contact surface with fuse and relay blades when seated
9 Compatible with blade width, length and thickness
10 Ability to be removed from cassette for repair w/o damage to locking feature of terminal
or cassette
Cassette Design:
11 Cavity design with proper lead-in and single orientation for terminals
12 Minimal cavity clearance -- no excess play (bias)
13 Positive locking features for terminals -- primary and re-enforcement
14 DLL-16 Compatible cavity tolerances with terminals, spacers and devices --- NO STUBBING
C170
15 Ability to remove relays, fuses, spacers and terminals without damage to any locking
features
16 Cavity and terminal alignment match fuse and relay perpendicularity (nominal and
min/max)
17 Proper insertion and retention forces for devices
18 Design allows spacer to dislodge partially seated terminals during locking into cassette

19 Design insures that spacer cannot be seated with trapped terminal

20 Minimal variation in frame/cassette interface for consistent position of relays and fuses

Spacer Design:
21 Matching nominal and min/max tolerances between terminals, cassette cavities and
spacers to insure optimum alignment of device blades with female terminals
22 Provide lead in (guide) for relay and fuse blades
23 Provide access to box of female terminal for circuit test and push test
24 Cannot be closed (locked) if any of the female terminals are trapped but not seated

25 Dislodges any partially inserted terminals during closure of spacer

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with PDB

Compliance
Num ID Concern Item to Check Y N Problem Description Action Taken
26 Provide ability to remove the spacer for repair without damage to locking features
27 Design spacer locks to insure flatness of entire spacer once seated -- no bowing of
spacer
Relay/Fuse Design:
28 Insure full tolerance alignment of device blades with spacer, cassette and terminals

29 Insure blade perpendicularity

30 Provide proper chamfer on all blades for lead in to spacer, cassette and female
terminals
Covers
31 All PDB shall bave a top cover with retention features to prevent components (fuses,
relays, etc) from being dislodged during part shipment, assembly into vehicle, vehicle
vibration, etc.
32 The maximum mating effort to fully attach the top cover to the PDB and show no false
lockups, must be less than or equal to 90 N
33 The top cover latch features shall be protected from accidental deflection during
shipping, handling and assembly.
34 All engine compartment PDB's containing fuses shall have provisions for a hinged top
cover or tether attachment.
35 The maximum effort to remove the top cover from the PDB shall be less than or equal
to 90 N.
36 Bottom covers shall be included for all engine compartment mounting
37 DLL-17 The bottom cover shall not have any sharp edges that can abrade the wiring
U377
38 DLL-18 The bottom cover shall not be capable of trapping wires between the cover and the
U377 PDB.
39 The cover shall have enough room for the wire bundle into the PDB.
Buss bars
40 DLL-19 The buss bar packaging shall avoid tangled buss bars
U377
41 DLL-36 The tolerance for buss bar dimensions and tolerances shall be consistent with the
U377 cassettes, and wedge design tolerances.
42 DLL 20 The bussbar must no have any exposed surfance that may have contact with any
U377 damage/ pinched wire.
Others
43 DLL-23 The tolerances for all mounting devices (brakets/ insert frame holes) were reviewed to
U377 be consistent with the vehicle dimensions.

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with PDB

Compliance
Num ID Concern Item to Check Y N Problem Description Action Taken
44 DLL-25 Tie straps or tape hankings are used to control de length and dress of the circuits into
U377 the PDB to pvernt wires to be trapped by the covers
45 DLL-28 Dimensions of the battery cables to be assembly to the PDB consider the proper
U377 dimensions and tolerances to avoid tight or excessive length wires.
46 DLL-29 The battery cables are designed as pokeyoke to avoid be mistakely assembled in the
U377 worng PDB terminal

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Manufacturing Concerns with Packaging

Compliance
Num ID Concern Item to Check Y N Problem Description Action Taken
1 DLL-45 Are there no critical connectors directly under pressure from heavy components or
C170 other heavy sections of the harness that may cause deformation or warping on
connectors?
2 Are there no grommets directly under pressure from heavy components or other heavy
sections of the harness that may cause deformation or warping on grommets?

3 Are the orientation and position of all locking tabs good such a way that breakage of
locking ramps and fingers are prevented?
4 Are all the connectors and takeout branches free from any entanglement with any part
of the hanked harness during the packaging and unpacking process
5 Are the orientation of the connectors in such a way that the terminals wont be
deformed or broken
6 Are all folded section of the harness away from the splices area..
7 Are the clips that are spot taped secure even after hanking and folding the harness.

8 DLL-37 Are the hanking and packaging feasible for the manufacturing plant
U251

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007

 Checklist Revision Log

Revision
Description Date Approvals
00 - Initial release 02/28/07 Alfonso Delgadillo
PE Divisional Mgr.
01 - U251 & U377 Lesson learned incorporated 03/15/07 Alfonso Delgadillo
- PDB section added PE Divisional Mgr.
- Revision log added
02 - Packaging section Added 3/16/2007 Alfonso Delgadillo
PE Divisional Mgr.
03 - Wording of each question were reviewed to insure are easy to 3/26/2007 Alfonso Delgadillo
understand by the user PE Divisional Mgr.

Design for Manufacturing Guidelines Checklist Rev 03 03/26/2007