Case Study
Harness Assembly Instructions & Documentation Standardization
Created clear harness assembly instructions to improve build consistency and reduce ambiguity during integration.
Problem
Harness builds relied on tribal knowledge and inconsistent documentation, creating confusion during assembly and handoff between design, manufacturing, and integration, increasing the risk of rework.
Role
Manufacturing Engineering InternBlue Canyon Technologies • May–Aug 2025
Assembly documentation and process support (no electrical design ownership).
Tools & Skills
Results
- Created standardized harness assembly instructions with defined routing, labeling, and step-by-step build guidance.
- Incorporated technician feedback to clarify ambiguous steps and refine documentation before integration.
- Improved repeatability and reduced reliance on tribal knowledge during harness assembly and handoff.
No proprietary drawings or part identifiers are shown.
Where it started
Harness drawings and assembly instructions existed, but standards were inconsistently applied across programs and variants.
Assembly instructions often lacked photos, variant-specific detail, or clear linkage to documented harness standards, leaving gaps for less experienced technicians.
As a result, builds relied heavily on technician experience, and quality outcomes varied by model and individual familiarity.
How I contributed
Updated harness drawings to align with existing documentation standards and ensure consistency between released drawings and written assembly guidance.
Developed a more detailed harness assembly instruction structure with step-by-step procedures that could be reused across multiple harness variants and programs.
Defined modular procedures (e.g., routing, termination, labeling, inspection) so each harness referenced only the applicable steps, improving clarity without duplicating content.
The updated instructions enabled less experienced technicians to build harnesses to specification, improving first-pass quality and reducing NCRs tied to assembly variation.