Endego’s expertise in complete wire harness car development for TIER1.

Challenge: Meeting stringent standards and processes

A TIER1 supplier, commissioned by a renowned OEM to develop a complete vehicle from the concept phase, including developing electrical harnesses according to the VOBES process and complying with OEM standards (VW6000, VW80000). This required considering the feasibility and optimization of the production process for individual harnesses, their assembly into a complete product, and the potential for installation in a vehicle still in the early stages of development, while also maintaining the required quality, minimizing unit production costs, and ensuring parts were not susceptible to changes in later project stages.

Solution: Endego’s integrated team and advanced simulations

Endego assembled a specialised team to address these challenges. Our approach included:

• Specialized teams: the team developed HV and LV harnesses, ensuring compliance with VW6000 and VW80000 standards and optimizing production costs.
• Project Management: we provided a Project Manager along with a team to manage the project, embracing the ASPICE and VOBES processes.
• Simulations: using IPS, our team conducted thermal and durability simulations, virtual tests, and dynamic harness simulations.
• Cross-department communication: to ensure proper packaging, we managed synchronization with the client’s Body-In-White, Interior, and Exterior departments.
• EMC testing: the concept was checked for EMC compliance to prevent electromagnetic interference.
• Compliance: adhering to the VOBES process and conducting ISO26262 Functional Safety analyses.

Technologies: Leveraging multiple tools

Our solution utilised advanced technologies and methodologies:

• EB Cable and LDorado: For detailed harness design
• CATIA EHI and ELENA: For 3D routing design and integration.
• Teamcenter and Architect: For project management and documentation.
• Functional Safety (FuSa): Incorporating safety principles to meet rigorous standards.
• IPS and ASPICE: For simulations and adherence to process standards.

Expectations and standards for complete car development:

• Stringent compliance: There is an increasing need to adhere to specific standards and processes.
• Advanced simulations: Growing reliance on simulations for design validation and performance testing.
• Cross-department collaboration: Emphasis on seamless communication between different vehicle development departments.
• Functional safety: Incorporating comprehensive safety analyses to meet industry standards.
• Cost efficiency: Focus on maintaining high quality while minimising production costs.

Endego’s competences

Endego’s competences in vehicle harness design and development are extensive. Our capabilities include:

• Process expertise: Assisting clients in implementing specific development processes to streamline project execution.
• Production implementation: Implementing products into production efficiently to ensure seamless integration and high quality.
• Electrical diagrams: Creating electrical diagrams that serve as the blueprint for harness designs.
• Packaging
• 3D models and 2D drawings: Developing 3D models and 2D manufacturing drawings .
• Component design: Designing and optimizing individual components.
• Simulations
• FuSa

For more detailed insights into our competencies, visit our Wiring Harness page.

Endego’s recent project with a TIER1 supplier showcases our ability to meet complex requirements and deliver successful outcomes. By leveraging advanced technologies and our extensive expertise, we ensured the project adhered to stringent standards and was completed on time.

For inquiries or more information about our services, don’t hesitate to get in touch with us.