Wiring Harnesses
Whether you already have a wiring harness designed, or require us to design and build your wiring harness, we ensure you get the highest quality harness, delivered on-time at a competitive price.
bf1systems prides itself on delivering the highest levels of service, quality, competitive pricing and on time delivery. We can offer innovative packaging solutions incorporating complex enclosure designs that can be produced by our in-house composites department, alongside more traditional wiring harness assemblies. As well as producing on vehicle harnesses, we also supply wiring for off-car applications, such as wind tunnels, pit equipment and test rigs.
Design
With our senior design team (averaging over 17 years of harness design experience each), we ensure that every wiring harness is designed to suit your particular application. From connector choice, wire selection type and gauge, through to sleeving, lay-up and layout, we ensure that we work closely with all our customers to ensure that every part of the harness is optimised for you. This type of collaboration allows bf1systems to capture all the requirements of the client, which, in turn ensures that the end product fits and functions with optimum performance and ultimate reliability.
Our engineers regularly travel out to customers for every stage of the project, from concept to the first fire-up.
Drawings can be taken from customers and modified into the bf1systems design format, or drawn from scratch in this format.
With in-house designers using AutoCAD, SolidWorks, Visio, CATIA V, Altium Designer, and in-house bespoke drawing checking software, not only are we able to develop traditional harnesses, but also complex enclosures which incorporate wiring within them.
Our in-house software allows us to automatically check all harness drawings, to ensure they are error free. The software also allows us to automatically generate Bills Of Materials (BOMs), wire cut lists and the netlist which is pre-loaded into the Cirris tester, all of which improve efficiency and reduce the time it takes to produce your wiring harness.
Production
With over 25 full time wiring harness production technicians, bf1systems has one of the largest harness resource pools available in the industry.
Builds ranging from simple test leads, through to full chassis harnesses can all be accommodated, with short lead time builds posing no problems.
To help with fast production, bf1systems holds stock of a large range of wire, sleeving and all other key components to prevent long lead times from holding up builds. We also have strong relationships within our supply chain to manage connector and other key components, which assists us to run a lean, efficient, cost effective operation.
The harness workshop is divided into teams, each overseen by a project leader. These teams are typically allocated to specific customers to ensure continuity between builds. Specific customer build requests are handled by updates to our internal Codes of Practise (CoP) to ensure that all staff working on a customer’s part are operating to the same standard
bf1systems offer its customers service and support capabilities. All design and test records are maintained for a minimum of 10 years so as harnesses can be returned for service, repair and full electrical test. In addition, we can provide technician support to customer premises or at other locations such as race circuits. We can also provide wiring harness basic training and knowledge to assist with ‘in-house’ terminations and builds.
Quality
bf1systems follows a ‘right first time approach’ to production with each assembly being subjected to a 100% electrical and visual inspection by a dedicated team of independent test and inspection technicians. This focus on quality ensures that our assemblies conform to the required specification and are delivered ready to plug-and-play straight from the box.
All harness technicians undergo a rigorous training programme, and some have in excess of 15 years’ experience in the manufacture of motorsport wiring harnesses.
The key harness design and manufacturing process controls include:
- Harness mock-up service available
- Circuitry and pin-out drawings
- Lay out drawings
- First-off/prototypes approval procedures
- Bills Of Materials
- Cirris Test files
- Cirris Test Lead files
- Build notes procedures utilised and backed up by extensive Codes Of Practice
- Test procedures
- Special packing reviews carried out
- FMEAs carried out as required
- Drawing checker software utilised
- 100% electrical tests carried out using Cirris by independent QC Team
- 100% visual and dimensional checks carried out
- In process inspections carried out
- Customer specification bench tests and fitting tests carried out as required
All records are kept for 10 years, meaning that harnesses can be returned for servicing, and tested to the same standard as they were when they were first produced.
