Enhancing Safety-Critical Assembly Processes through Electrical Testing: Advanced Manufacturing Solutions for Wire-Harness Assembly in Treadmill Components

Authors: Dhrudipsinh Dabhi

DOI: https://doi.org/10.5281/zenodo.14123282

Short DOI: https://doi.org/g8qtt7

Country: USA

Full-text Research PDF File:   View   |   Download

Abstract: The misalignment of safety-critical components can have serious consequences, particularly in consumer products such as treadmills. In this study, I investigated an assembly issue in treadmill plastic components that allowed wire-harness bases to be seated in either correct or incorrect orientations. The problem posed a significant safety hazard, as an incorrectly seated wire harness would prevent the stop-button safety feature from functioning correctly, potentially endangering users. Immediate corrective actions were taken to fix the problem both at my company and at the customer's site. Two long-term solutions were proposed: a design change and an ampere test. The customer chose to implement the ampere test for future production, and this solution was verified to ensure proper assembly in all future lots.

Keywords: Wire-harness assembly, safety switch, treadmill component, ampere test, assembly misalignment, corrective action, preventive action

Paper Id: 231539

Published On: 2020-10-07

Published In: Volume 8, Issue 5, September-October 2020

Share this