Wiring Harness

The wiring division is one of the most vertically integrated business divisions of Motherson, which provides it a huge competitive advantage. It helps to control the quality of the products, enables better cost control and aids in reducing the delivery time. It also reduces the risk of relying on tier II partners for critical inputs. 

The capability of designing mechanical parts and manufacturing of jigs, fixtures, applicators, circuit checking and assembly boards, supported by state-of-the-art facilities for the wiring harness and component testing, makes the company a full system solutions provider.

Wiring harness components

• Wires
• Terminals 
• Connectors 
• Caps and sleeves 
• Grommets 
• Clamps and binders 
• Junction boxes 
• Fuse boxes 
• Protectors 
• Relay boxes 
• Wire seals 
• High tension cords 
• Battery cables 
• Mechanical assemblies in house production of mechanical parts 

Power distribution modules are designed to deliver power intelligently from the main power source to remote systems throughout the vehicle. DC/DC converters, battery management systems, and power distribution units are examples in-vehicle electronics where the company is developing optimised and in some cases customised customer-specific solutions.

Wiring Harness Division develops and manufactures electrical cabinets, power packs, converters and drivers desks and other components for rolling stock, the energy industry and the material handling industry. Electrical cabinets and power packs applications include passenger trains, light rail vehicles, metros, locomotives, wind energy, port solutions, machine constructors and stationary power systems.

The division has also expanded its product portfolio and delivers high voltage products for electrical buses, contributing to sustainable transportation.

Division also develops a unique ERP solution, which enables managing the complexity of the product & operating environment and delivers high quality individually tailored products and thousands of product variants with short delivery time. A unique feature in Wise ERP system is the real-time item balance forecast, providing instant data required in sales, manufacturing and purchase processes. Information on purchase and production demands, possible delays, rescheduling or cancellation needs is immediately available to different parties without having to perform a separate MRP run. Wise is currently being used in the electronics industry, wiring harness, machine, equipment, mechanics and printed circuit board manufacturing as well as in the environmental technology industry. 

• Process innovation to enhance efficiency and effectiveness of the manufacturing process is the focal point for the production engineering team.
• Comprehensive in-house production engineering capabilities that include process design, crimp tooling, assembly tooling, test tooling and special purpose machine designing and development capabilities.
• In house tool design and development capabilities help in keeping controls on quality, cost and lead times.
• Process design is focused on the elimination of raw material waste, optimal consumption of power, air and water

• ISO/IEC 17025:2017 [NABL] Certified Laboratory equipped to conduct various kinds of design validation testing required by different OEMs.
• Ability to perform tests as per various National & International standards (IS, ISO, ASTM, JIS, JASO, etc.) including  OEM specific standards.
• Analytical ability of equipment which helps in swiftly & accurately establishing the cause of any failure for product & process improvisation. 
• Calibration facility is ISO/IEC 17025:2017 [NABL] certified, which ensures all measuring and test equipment used in the laboratory and manufacturing plants always meet the established calibration standards to ensure the integrity of the test results.

• Conveyorised assembly lines and capability of specialised processes such as braiding, over moulding, heat resistance welding, ultrasonic welding online printing etc.
• Advanced material planning systems to enable sequence production and efficient use of materials
• Digital assembly boards that range from single lead simple assemblies to large multi-hundred lead assemblies that include small to large complex connection systems
• Highly skilled human resources with EASY training programs to build necessary skillsets for generic and special manufacturing skills 
• Principles of ergonomics are practiced while designing workstations and assembly lines
• Equipment is built with appropriate guarding and regular training provided to employees to ensure the highest level of safety to prevent injuries to them. Environmental management systems and processes in place to reduce the use of energy and water as well as the amount of wastes (hazardous and non-hazardous) generated 

The combination of design, development, prototyping & validation throughout the entire development period, quality, infrastructure, technology helps Motherson emerge as a complete service provider in wiring harnesses to its customers. The driving force behind this is to facilitate proximity for supplying just-in-time to the customer wherever they are and cater to their requirements.