One of the challenges in testing wire harnesses is maintaining control of the testing process. Typically, the testing process for wire harnesses is not fully automated. Operators manually connect and disconnect wire harnesses from the test fixture. After a wire harness has been tested, it must be categorized as having passed or failed, and the operator must segregate failed harnesses from good ones.
At times, an operator may fail to properly segregate a failed wire harness, causing significant problems downstream. Another potential problem occurs when an operator fails to wait until the test is completed and removes a partially tested wire harness from the test fixture. Selecting the wrong test program is also a potential problem.