Production Process

At WIRES, mass production follows strict standard operating procedures to ensure consistent quality and reliability.

Step 1: Crimping

Terminals and wires are crimped using semi-automatic or fully automatic equipment. Quality checks include:

  • Crimp height
  • Crimp width
  • Pull force testing
Semi-automatic crimping

Semi-automatic crimping


Fully Automatic Crimping

Fully Automatic Crimping

Step 2: Assembly

Pre-assembled semi-finished wires are arranged on manufacturing fixture boards to ensure accurate:

  • Branch routing
  • Harness dimensions
  • Assembly positioning

Assembly of Dedicated Manufacturing Fixture Boards

Step 3: Inspection & Detection

  1. Appearance inspection:
    Form-fitting gauges are used to check for:
    • Wire damage
    • Exposed conductors
    • Loose fasteners
  2. Electrical testing:
    Dedicated testing equipment verifies circuit conductivity and connection accuracy.
Appearance and Dimension Inspection

Appearance and Dimension Inspection


Functional Testing

Functional Testing

Step 4: Packaging

  • Cartons are lined with dust-proof bags and equipped with 50g desiccant packs
  • After reaching the standard packing quantity, products are secured with cardboard covers
  • Dust-proof bags and cartons are then fully sealed
Lay flat dust-proof bags inside the cardboard box

Lay flat dust-proof bags inside the cardboard box


Pre-fix with a coverboard

Pre-fix with a coverboard

Step 5: Shipping

Finished products are prepared for shipment according to customer logistics requirements and transportation standards.

Goods awaiting shipment

Goods awaiting shipment