1. A CMM Level 5 Company
C & C System Over View Harness
General Terminology
Manufacturing Steps
C & C System
Sub System Overview

2. A CMM Level 5 Company
General Terminology
What is Harness ?
Harness is a composite electric circuit of automobile. It works as
nervous system of a vehicle
Harness Operations
Cut & Crimp
Cut
Crimp
Splice
Part Fitting
Sub Assembly
Assembly
Inspection
Packing & Dispatch

3. A CMM Level 5 Company
APPLICATION OVER VIEW
This system computerizes Wire Harness manufacturing and integrates
the manufacturing process such as C&C production schedule,
Optimization process, lead wire C&C instruction and C&C production
output.
PURPOSE OF THE SYSTEM DEVELOPMENT
Improvement of control accuracy
Reduction of the office work load
Reduction of manual operation time
Stable manufacturing
The best operation instruction
Introduction of C&C

4. A CMM Level 5 Company
International
VAN Terminal
C&C
Server
C&C ClientsLaser
Printer
C&C System
System Composition
Komax
Networked
Machine

5. A CMM Level 5 Company
C&C SYSTEM (Network Overview)
C&C Server
(SQL Server 2K)
Lead
Stores
HP LaserJet 8150
C&C Client
PDT
Barcode
Scanner
C&C
Planner
C&C Client &
WPCS Format
Generator
HP LaserJet 8150 TEC
PRINTER
(For EFU Tkt)
C&C Client
LAN
WPCS Enabled
Wire processing
machines
DHS Server
(SQL Server 2K)

6. A CMM Level 5 Company
Sub System Over View
1. Send & Receive Data Sub System
2. BOM Maintenance Sub System
3. C & C Daily Production Schedule (CPS) Sub System
4. Optimization Sub System
5. Production Output Report Sub System
6. Master Files Maintenance Sub System
7. CUP Sub System
8. Stock Taking Sub System
9. GBG Sub System
This system consist of following modules

7. A CMM Level 5 Company
Send & Receive Data Sub System provide the functions to get BOM data and to import
to the C&C system.
Send & Receive Data Sub System
BOM -: Bill Of Material for C&C System is the data prepared by SWS for design of
new products.
B O M D a t a H e ig h t D a t a
B O M fo r C & C S y s t e m

8. A CMM Level 5 Company
BOM List Of Not Set Height
C&C Clients
List of not set MachineNo.
Wire Type Change List
New Wire List
New Terminal List
New Material List
BOM Upload List
BOM Upload Error List
Product
BOM
Splice
BOM
Material
Detail BOM
MH
BOM
Material
BOM
Circuit
BOM
Circuit
Grp Detail
Terminal
Material
Set
Machine No
Height
BOM

9. A CMM Level 5 Company
Ｏ
DENGRP.TXT
Ｎ
ＣＰＳ
Height
Upload List
Height
ＷＯＮ
ＣＰＳ
CircuitBOM
Local
Height
C
KYOZKN.TXT
TANZKN.TXT
HGTKAN.TXT
Height Upload

10. A CMM Level 5 Company
BOM Maintenance Sub System
BOM Maintenance is to add some production condition (Ex Machine Condition)
BOM data can be displayed, modified, added, deleted and copied.
BOM related Lists are displayed. (Circuit BOM List, Terminal Usage List and so on.

11. A CMM Level 5 Company
Output Report for BOM sub system
Report Name Report Explanation
Product BOM List When you want to confirm the Product BOM, use this list.
Circuit BOM List When you want to confirm the Circuit BOM, use this list.
Wire Requirement List When you want to check the ‘Wire Requirement’ per all
product No / specific product No / CPS , use this list.
Terminal Requirement
List
When you want to check the ‘Terminal Requirement’ per all
product No / specific product No / CPS , use this list.
Terminal Usage List When you want to check the ‘Terminal Combination Pattern’
per all product No / specific product No / CPS , use this list.
Wire & Teminal Usage
List
When you want to check the ‘Wire & Terminal Combination
Pattern’ per all product No / specific product No / CPS , use
this list.
Material Requirement List When you want to check the ‘Material Requirement’ per all
product No / specific product No / CPS , use this list.

12. A CMM Level 5 Company
C & C Daily Production Schedule (CPS) Sub System
Production
Schedule
C&C
Schedul
e
Production
Schedule List
List
1
4
7
2
5
8
3
6
(1)
(2)
(3)
Output CPS Report
CPS Arrangement
The Registration of C&C schedule is necessary
to keep the C&C System based on the
production schedule.
CPS Sub System includes the function to
register the C&C schedule for scheduling staff
according to customer purchase order.
C&C start date and issue date
You should input issue date every “Lot No” or
“Work Order No” when you register the C&C
schedule.
Each C&C start date and short code is set by
C&C system automatically.
Decision of C&C start date
You can specify the L/T in every process
pattern.
* L/T abbreviation for “Lead Time”.
Single Wire L/T
Splice processing L/T
Non Single Wire processing L/T (Pre Insert, Manual Crimping)
Special Wire L/T

13. A CMM Level 5 Company
How to get a start date in each process
(1). Single Wire L/T = Single Wire L/T
(2). Splice Wire L/T = Single Wire L/T + Splice processing L/T
(3). Non Single Wire L/T = Single Wire L/T + Non Single processing L/T
(4). Special Wire L/T = Special Wire L/T
(Ex.)
 1. Single Wire L/T 1 day
 2. Splice processing L/T 1 day
 3. Non Single Wire processing L/T 2 days
 4. Special Wire L/T 4 days
 Issue Date Nov 15
Nov 11th
Nov 12th
Nov 13th
Nov 14th
Issue Date
Single Wire 1
Splice Wire 1 2
Non Single Wire 1 2 3
Special Wire 4
CPS Sub System

14. A CMM Level 5 Company
Optimization Sub System
BOM
EFU Extraction
Check List
1
2
3
(1) EFU Extraction
(2) Optimization
(3) Machine working load
Arrangement
CPS
Data
4
EFU
(4) Report Output
The brief of Optimization Sub System is as the follows.
Daily working data is extracted from CPS data and after
optimization EFU data is prepared.
EFU data is ordered in consideration of change time or EFU
No or Process Pattern.
Optimization related reports are available. (Daily Working
Report, Work Load List and so on

15. A CMM Level 5 Company
Manual Optimization
You can arrange the auto optimization result manually.
Moving inside the same machine
The order change on the specific machine
Moving between the machines
EFU data moving between the specific machines
Optimization Sub System
Work Load List
Work Load Detail List
C&C Instruction Sheet
Lead Set-up report
Daily Working Report
Wire Requirement List
Wire Preparation List
Terminal Requirement List
Terminal Preparation List
Material Requirement List
EFU Sheet (Normal)
EFU Sheet (Emergency)
This list is to confirm the man-hour and set-up time and production quantity per shift and machine.
(This list is used for machine working load arrangement.)
This list is to confirm the circuit information and man-hour and set-up time and production quantity
per shift and machine.
(This list is used for machine working load arrangement.)
EFU
This is a daily report to fill the EFU order and defect information and actual height information.
This list is used for wire preparation.
Wire type, wire size, wire flex, production quantity is outputted.
This list is used for wire preparation.
Wire type, wire size, wire flex and production quantity is outputted per machine..
This list is used for terminal preparation.
Directions sheet for C&C operator.
This is EFU for emergency.
Specify the product no and circuit, and output the EFU one by one.

16. A CMM Level 5 Company
Production Output Report Sub System
Daily Working
Report
(1) Input Actual Result
EFU Half
Ticket
(1) Refer to the Actual Result
Progre
ss
Status
Screen
You Input actual C&C result of operator by the Daily
Working Report.You register actual C&C result of EFU by
using barcode reader.
Refer to the C&C completion status on the C&C
status screen if necessary.
Output Reports are as follows.
1.SKT List
2.Efficiency List(per M/C or per Operator)
3.Defect List
Status Enquiry is obtained along with the information details
regarding the
A. Circuit giving Terminal as well as Material Description
B . Defect giving the defect quantities corresponding to the defect
codes
4.Machine Maintenance List
5. Daily Working Report

17. A CMM Level 5 Company
Master Files
Maintenance
Sub System
We must adjust some manufacture
conditions again in this sub system
when produces the new product or
introduce a new auto C&C machine
and so on
Standards of the factory can be decided.
Standards of machine can be decided.
Access limit of user can be decided.
(Standard Data) Capacity of factor
C&C Machine OperatorTerminal
Wire
Standa
rd
Tables
(1) Input the standard data
Machine Cutting (Type/Size)
Manual Cutting (Wire Length)
Terminal
Material
Applicator
Pre-Ins Material
Wire Bunch Class
Wire Bunch Condition
Process
Machine No
Machine Setting
Machine Condition
Circuit Condition
Wire Bunch Size
Unnecessary BOM data
Change Wire Type
Wire
Calendar
Lead Time
Serial No
Operator
Defect Code
Spoilage Code
M/C Std Run Time
Height Check Screen
O/H Terminal
Terminal Retention
Local Height
User ID
PGM Function
PGM Function Relation
Function CTL
BOM
Others
Process
Decision
Machine
Decision
Others
Working Day
Lead Time
Operator
Name
User ID/Name
PGM ID/Name
User and PGM
Relation
Send &
Receive
data Sub
System
CPS Sub
System
POR Sub
System
Height
Relation
System

18. A CMM Level 5 Company
CUP Sub System
Purpose of the CUP subsystem is to introduce an imaginary product using multiple Products which
have similar circuit Information common at different level.
Common Product is a combination of products which share some common circuit information.
Products which share some common circuit information and combine together form a common
product, are called component product.
Product #A
Product #B
Product #C
Common Circuits in Product #B & #C
Common Circuits in Product #B & #A
Common Circuits in Product #A & #C
Common Circuits in Product #A, B & #C
Common Product

19. A CMM Level 5 Company
Stock Taking Sub System
This subsystem can support the stocktaking job for
C&C area.
Prints the stocktaking check sheet.
Staffs for stocktaking fill this check sheet with
circuit or material quantity in C&C area.
There are 4 method for filling the check sheet.
 Circuit Group and quantity
 Circuit and quantity
 EFU Serial No and quantity
 Circuit and material quantity

20. A CMM Level 5 Company
GBG Subsystem
Unnecessary data that it passed through the
specified term is exported to text file and
compress. After this, these data is deleted
from C&C database.

21. A CMM Level 5 Company
To meet the requirements of SEWS-E (Sumitomo
Electric Wiring System Europe) following 2
modules has been added in the Standard C&C
System.
Module: 1
• STOCK CONTROL SYSTEM
( SEWS-E system )
Module: 2
• MRP SUBSYSTEM
( SEWS-E system )
SEWS-E C&C (System Overview)

22. A CMM Level 5 Company
SWS/UK
HEIGHT
DATA
I.H.S
CAD
DATA
LESZNO DEVA TOPOLCANYRAWICZ
CUTTING
MACHINE
ORASTIE
ENG
DEPT
ENG
DEPT
ENG
DEPT
ENG
DEPT
ENG
DEPT
MACHINE
NETWORK
MACHINE
NETWORK
MACHINE
NETWORK
MACHINE
NETWORK
MACHINE
NETWORK
CUTTING
MACHINE
CUTTING
MACHINE
CUTTING
MACHINE
CUTTING
MACHINE
LOCAL
MRP
&
LEADS STOCK
SYSTEM
ASSEMBLY
C&C
SYSTEM
C&C
SYSTEM
C&C
SYSTEM
C&C
SYSTEM
C&C
SYSTEM
SEWS-E C&C (System Overview)
ALBA
ENG
DEPT
MACHINE
NETWORK
CUTTING
MACHINE
C&C
SYSTEM

23. A CMM Level 5 Company
ASSEMBLY
PLANNING
ENGINEERING
I.H.S
C.A.D
HEIGHT
DATA
CST
PROCESSES
Standard
C&C
System
MPS
DATA
PRODUCT
B.O.M.s
HEIGHT
DATA
MACHINE
NETWORK
D.H.S
MPS
MACHINE TYPE DATA
CIRCUIT BOM DATA
STOCK DATA
MRP RESULT
MACHINE OPTIMISATION DATA
TICKET DATA
MACHINE NETWORK DATA
BUILD SCHEDULES
C&C SYSTEM
LEAD STORE
STOCK
SYSTEM
ASSEMBLY
ALSO NON
NETWORK
MACHINES
SEWS-E C&C (Data Flow)

24. A CMM Level 5 Company
C&C Assembly CPS
MRPCut Lead Stock Build Schedule
(Planned qty )
Safety Stock
DecreaseIncrease
DHS Assembly MPS
CC masterfile CC optimisation
Order Policy
Modifiers ( LT / Calendar etc )
Availability Reports
Decrease
Daily working report & Tickets
MRP Check
Report
LEAD STORES
C&C PROCESS
Suggested Cutting
Schedules After MRP
BOOK IN
BOOK OUT
KITTING
BUILD SCHEDULES
SEWS-E C&C (Stock/MRP Logic)

25. A CMM Level 5 Company
SEWS-E C&C (MRP Suggestion)
MRP Suggestions As on >> 10/02/03 <<
Common Product or Product Number : TOYDRLH ( example )
Bundle Qty MRP Suggestions
A Side B Side BECC CCVC 10/02/2003 17/02/2003 24/02/2003 Safety Stock Arrears Current Future 1 Week 1 Week 17/02/2003
#PO P79 0 60 240 240 240 60 0 0 240 0 240 60 240
#R1 JAV 0 60 240 240 240 60 0 0 240 0 240 60 240
$NE JAT 0 60 240 240 240 60 0 0 240 0 240 60 240
$NL JAU 0 60 240 240 240 60 0 0 240 0 240 60 240
$QE Q43 0 60 240 240 240 60 0 0 240 0 240 60 240
$QT Q17 0 60 480 480 480 60 0 0 480 0 480 60 480
$QU Q18 0 60 480 480 480 60 0 0 480 0 480 60 480
%Z3 #ZE 0 60 240 240 240 60 0 0 240 0 240 60 240
%Z3 &EA 0 60 360 360 360 60 0 0 360 0 360 60 360
%Z3 JAW 0 60 240 240 240 60 0 0 240 0 240 60 240
%Z3 Z62 0 60 240 240 240 60 0 0 240 0 240 60 240
%Z3 ZHU 0 60 240 240 240 60 0 0 240 0 240 60 240
*1 *2 0 60 480 480 480 60 0 0 480 0 480 60 480
JJJ PM1 0 60 240 240 240 60 0 0 240 0 240 60 240
JJJ PM4 0 60 240 240 240 60 0 0 240 0 240 60 240
JJJ PMZ 0 60 240 240 240 60 0 0 240 0 240 60 240
P64 P80 0 60 240 240 240 60 0 0 240 0 240 60 240
P65 P81 0 60 240 240 240 60 0 0 240 0 240 60 240
PNK PNM 0 60 240 240 240 60 0 0 240 0 240 60 240
PP4 PMW 0 60 240 240 240 60 0 0 240 0 240 60 240
R47 R86 0 60 480 480 480 60 0 0 480 0 480 60 480
R48 R52 0 60 480 480 480 60 0 0 480 0 480 60 480
0 0 6600 0 6600 1100 6600
0 0 2400 0 2400 400 2400
0 0 1440 0 1440 300 1440
0 0 2760 0 2760 400 2760
0 0 6600 0 6600 1100 6600
8
6
8
22
Total Sub Circuits
Total Circuits
Sub Circuits Quantity
Grand Total
Total Single Circuits
Total Splice Circuits
Past Due Suggestions
Total Quantity
Single Circuits Quantity
Splice Circuits Quantity
Circuit Details MPS Schedule Stock Profile Build Schedule
Both
Ends
Common
Crimp
Common
Circuit
Version
Code
MPS Scheduled
Line Issue dates
from DHS
MRP Suggested
Cutting Quantity
and Date
MRP Suggested
Cutting Quantity
outside of 5 Day
Lead Time
Cut Date
03/02/2003
Cut Date
10/02/2003
Cut Date
17/02/2003

26. A CMM Level 5 Company
SEWS-E C&C (MRP Status)
MRP Status As on >> 10/02/03 <<
Common Product or Product Number : TOYDRLH ( example )
Bundle Qty MRP Suggestions
A Side B Side BECC CCVC 10/02/2003 17/02/2003 24/02/2003 Safety Stock Arrears Current Future 1 Week 1 Week 17/02/2003
#PO P79 0 60 240 240 240 60 0 0 480 300 0 0 0
#R1 JAV 0 60 240 240 240 60 0 0 480 300 0 0 0
$NE JAT 0 60 240 240 240 60 0 0 480 300 0 0 0
$NL JAU 0 60 240 240 240 60 0 0 480 300 0 0 0
$QE Q43 0 60 240 240 240 60 0 0 480 300 0 0 0
$QT Q17 0 60 480 480 480 60 0 0 960 540 0 0 0
$QU Q18 0 60 480 480 480 60 0 0 960 540 0 0 0
%Z3 #ZE 0 60 240 240 240 60 0 0 480 300 0 0 0
%Z3 &EA 0 60 360 360 360 60 0 0 720 420 0 0 0
%Z3 JAW 0 60 240 240 240 60 0 0 480 300 0 0 0
%Z3 Z62 0 60 240 240 240 60 0 0 480 300 0 0 0
%Z3 ZHU 0 60 240 240 240 60 0 0 480 300 0 0 0
*1 *2 0 60 480 480 480 60 0 0 960 540 0 0 0
JJJ PM1 0 60 240 240 240 60 0 0 480 300 0 0 0
JJJ PM4 0 60 240 240 240 60 0 0 480 300 0 0 0
JJJ PMZ 0 60 240 240 240 60 0 0 480 300 0 0 0
P64 P80 0 60 240 240 240 60 0 0 480 300 0 0 0
P65 P81 0 60 240 240 240 60 0 0 480 300 0 0 0
PNK PNM 0 60 240 240 240 60 0 0 480 300 0 0 0
PP4 PMW 0 60 240 240 240 60 0 0 480 300 0 0 0
R47 R86 0 60 480 480 480 60 0 0 960 540 0 0 0
R48 R52 0 60 480 480 480 60 0 0 960 540 0 0 0
0 0 13200 7700 0 0 0
0 0 4800 2800 0 0 0
0 0 2880 1740 0 0 0
0 0 5520 3160 0 0 0
0 0 13200 7700 0 0 0
8
6
8
22
Past Due Suggestions
Total Quantity
Single Circuits Quantity
Splice Circuits Quantity
Circuit Details MPS Schedule Stock Profile Build Schedule
Total Sub Circuits
Total Circuits
Sub Circuits Quantity
Grand Total
Total Single Circuits
Total Splice Circuits
Both
Ends
Common
Crimp
Common
Circuit
Version
Code
MPS Scheduled
Line Issue dates
from DHS
MRP Suggested
Cutting Quantity
and Date +
Emergency 2 qty
MRP Suggested
Emergency 1
Quantity added to
Current ad-hoc tkts
made
Cut Date
03/02/2003
Cut Date
10/02/2003
Cut Date
17/02/2003

27. A CMM Level 5 Company
SEWS-E C&C (Stock System Leads Flow)
CC
BUILD
SCHEDULES
KOMAX
LEAD
STORES
SPLICE
SETS
&
SINGLE
SETS
SUB ASSEMBLY
HARNESS
ASSEMBLY
NETWORK
&
NON NETWORK
SINGLE
SETS
SPLICING
&
SPLICE SETS
98%
MINIMUM
ACCURRACY
98%
MINIMUM
ACCURRACY
MRP
CALCULATION

28. A CMM Level 5 Company
SEWS-E C&C (Data Maintenance)
• SAFETY STOCK MAINTENANCE AT FAMILY LEVEL ( CST PLANNER )
• SLOW MOVING STOCK MONITOR MAINTENANCE ( CST PLANNER )
• CST BUILD SCHEDULE MAINTENANCE 98% ( CST PLANNER )
• STOCK ACCURACY 98% ( LEAD STORES )
• MRP CHECK AND ANALYSIS ( CST PLANNER )
• MEASURES OF PERFORMANCE ( CST PLANNER )
• MACHINE CONSTRAINTS DATA (CST PLANNER )

29. A CMM Level 5 Company
SEWS-E C&C (Stock Processing)
• BAR CODE TRANSACTIONS
• BOOK IN FROM KOMAX , SINGLE / SPLICE LEADS
• SUB ASSY LEADS DIRECT TO SUB ASSY AREA
• MANUALLY BOOK IN LEADS FROM OTHER FACTORY
• BOOK IN SUB ASSEMBLY LEADS AFTER PROCESSING
• SCANNER DOWNLOAD CONVERTS BUILD SCHEDULES INTO STOCK QTY
• CIRCUIT AVAILABILITY TO CHECK STOCK
• CYCLE COUNTING TO MAINTAIN STOCK ACCURACY ( MIN 98% )
• BOOK OUT PRODUCTS OR CIRCUITS / SINGLE OR SPLICE
• CIRCUIT COMPARISON FUNCTION TO FIND ALTERNATIVE CIRCUITS
• BOOK IN FROM ASSEMBLY AREAS

30. A CMM Level 5 Company
SEWS-E C&C (Stock Processing)
• PROGRAM THAT CREATES CUTTING SEQUENCE
• PROCESSES “SETS” OF HARNESSES
• DESIGNED FOR DAILY / WEEKLY CUTTING
• SEQUENCE LOGIC BASED ON MINIMUM CHANGEOVERS
• ALLOWS MANUAL OPTIMIZATION TO M/C SEQUENCE
• “ SETS “ TRACKING BY LINE ISSUE DATE
• AUTO CPS FROM DHS SYSTEM
• CREATES COMMON CIRCUIT OPTIONS
• MRP GENERATED CUTTING SCHEDULE
• LEAD STOCK VISION
• SAFETY STOCK FUNCTIONALITY
• LEAD AVAILABILITY REPORTS
• SLOW MOVING STOCK MONITOR
• LEAD MATCHING FUNCTIONALITY
• BAR CODE SCANNING TRANSACTIONS
• STOCK COST INTERFACE WITH DHS

31. A CMM Level 5 Company
End Of Slide
Thank You