AUTOMOTIVE WIRING HARNESS ASSEMBLY NC II – TESDA COURSE MODULE

TRAINING REGULATIONS FOR AUTOMOTIVE WIRING HARNESS ASSEMBLY NC II

The TESDA Course in AUTOMOTIVE WIRING HARNESS ASSEMBLY NC II consists of competencies that a person must achieve to select and classify materials and parts for assembly of wiring harness; perform cutting and stripping of electrical wires; perform crimping and soldering of terminals and perform tying, taping and finishing of assembly wires.

This Qualification is packaged from the competency map of the Automotive Industry (Manufacturing sub-sector)

A student who has achieved this Course in AUTOMOTIVE WIRING HARNESS ASSEMBLY NC II is competent to be:

• Automotive Wiring Harness Assembler

AUTOMOTIVE WIRING HARNESS ASSEMBLY NC II – TRAINING AND REGULATION MODULE

Course Title: AUTOMOTIVE WIRING HARNESS ASSEMBLY
Level: NC II
Nominal Training Duration : 134 Hours

This TESDA course is designed to enhance the knowledge, skills and attitudes of an individual in the field of automotive wiring harness assembly in accordance with industry standards. It covers competencies such as: select and classify materials and parts for assembly of wiring harness; perform cutting and stripping of electrical wires; perform crimping and soldering of terminals and perform tying, taping and finishing of assembly wires.

TRAINEE ENTRY REQUIREMENTS

Trainees or students wishing to gain entry into this course should possess the following requirements:

• can communicate both orally and in writing; and
• physically and mentally fit

This list does not include specific institutional requirements such as educational attainment, appropriate work experience, and others that may be required of the trainees by the school or training center delivering the TVET program.

COMPETENCIES REQUIRED IN AUTOMOTIVE WIRING HARNESS ASSEMBLY NC II

This units of competency comprising this qualification include Basic, Common, Elective and Core Competencies.

To obtain this TESDA course in  Automotive Wiring Harness Assembly NC II, all units prescribed for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (96 Hours)
ALT827324	Select and classify materials and parts for assembly of wiring harness
ALT827325	Perform cutting and stripping of electrical wires
ALT827326	Perform crimping and soldering of terminals
ALT827327	Perform tying, taping and finishing of assembly wires
UNIT CODE	COMMON COMPETENCIES (20 Hours)
ALT311202	Perform Mensuration and Calculation
ALT742201	Read, Interpret and Apply engineering Drawings
ALT723201	Apply Appropriate Sealant/Adhesive
ALT723205	Perform Shop Maintenance
UNIT CODE	BASIC COMPETENCIES (18 Hours)
500311105	Participate in workplace communication
500311106	Work in a team environment
500311107	Practice career professionalism
500311108	Practice occupational health and safety procedures

CORE COMPETENCIES

UNIT OF COMPETENCY: SELECT AND CLASSIFY MATERIALS/PARTS FOR ASSEMBLY OF WIRING HARNESS
UNIT CODE : ALT827324

This competency unit covers the ability to select and identify materials/parts of a wiring harness in accordance with the company procedure. This competency also includes the delivery of the materials/parts to assembly line

1. Read and understand job sheet
   • Job sheets and manual instructions are understood and followed correctly
2. Select and classify materials/parts for the job
   • Materials/parts list is read and interpreted to establish requirements for the job in accordance with the instructions or job sheets to company standard operating procedures
   • Materials/parts are picked-up by matching part number, wire gages/sizes, appearance, color of electrical wires in the warehouse bin/container and floor stack areas
3. Deliver materials/parts to assembly line
   • Appropriate handling equipment are used ensuring for the safety and maintaining proper identification of materials/components when delivered to assembly line
   • Materials/parts are delivered into their respective working station in accordance with the company’s assembly station area/layout

UNIT OF COMPETENCY: PERFORM CUTTING AND STRIPPING OF ELECTRICAL WIRES
UNIT CODE : ALT827325

This competency unit covers the ability to perform cutting and stripping of electrical wires to specification that forms as a part of electrical harness of an automotive vehicle

1. Select and use tools and equipment / machine
   • Tools and equipment are selected to meet job requirements.
   • Tools and equipment are checked to ensure they are in good working order.
   • Appropriate cutting/stripping machines are selected and used in accordance with OH&S requirements
2. Cut and strip electrical wires
   • Electrical wires are cut to the prescribed or specified length using cutting machines
   • Insulators from both ends are removed/stripped by use of stripping machine
   • Workflow and production output are recorded and maintained
3. Inspect cut and strip portion
   • Inspection procedure is undertaken to standard operating procedures
   • Inspection results are reported/recorded to standard operating procedures as required
4. Clean up the area
   • At the end of the shift, cleaning up of working area is done to maintain cleanliness and orderliness of the shop floor area

UNIT OF COMPETENCY : PERFORM CRIMPING AND SOLDERING OF TERMINALS
UNIT CODE : ALT827326

This competency unit covers the ability to perform crimping and soldering of terminal plate into electrical wires to specification that forms as a part of electrical harness of automotive vehicles

1. Prepare materials for soldering
   • Materials preparation instructions are followed
   • Materials are prepared using correct tools and equipment, materials and procedures
   • Materials are prepared to specifications using instruction or standard operating procedures
2. Crimp terminals
   • Terminals of different kinds are connected to the wire stripped by crimping parts on terminals by use of crimping machine
   • Workflow and production output are recorded and maintained
3. Solder materials
   • Correct soldering techniques, procedures, materials and soldering tools are selected
   • Materials to be jointed, mounted, shaped are to specification using standard operating procedures
   • Solder is applied using correct and appropriate techniques
   • Where appropriate, excess material is removed using correct tools and techniques
   • Procedures for the protection of components are observed according to standard operating procedures.
4. Inspect crimp and solder joints
   • Inspection procedure is undertaken to standard operating procedures
   • Inspection results are reported/recorded to standard operating procedures as required
5. Clean up the area
   • At the end of the shift, cleaning up of working area is done to maintain cleanliness and orderliness of the shop floor area

UNIT OF COMPETENCY : PERFORM TYING, TAPING AND FINISHING OF ASSEMBLY WIRES
UNIT CODE : ALT827327

This competency unit covers the ability to perform tying, taping and finishing of assembly wires as part of assembly process on forming board to specification that forms as a part of electrical harness of an automotive vehicles

1. Prepare materials for the job
   • Materials are prepared in accordance with instructions
   • Materials are prepared using tools, equipment, materials and procedures appropriate to the task
   • Materials are prepared to specifications using instruction or standard operating procedures
2. Perform tying, taping and finishing on assembly wires
   • Materials to be tied, taped and finished are to specification using standard operating procedures
   • Tying, taping and finishing of assembly wires process is applied using appropriate tools and techniques
   • Where appropriate, excess material is removed using correct tools and techniques
   • Procedures for the protection of components are observed according to standard operating procedures.
   • Workflow and production output are recorded and maintained to standard operating procedures
3. Inspect jointed assembly wires
   • Inspection procedure is undertaken to standard operating procedures
   • Inspection results are reported/recorded to standard operating procedures as required
4. Clean up the area
   • Cleaning up of working area is done to maintain cleanliness and orderliness of the shop floor area

COMMON COMPETENCIES

UNIT OF COMPETENCY: PERFORM MENSURATION AND CALCULATION
UNIT CODE : ALT311202

This unit includes identifying caring, handling and use of measuring instruments.

1. Select measuring instruments
   • Object or component to be measured is identified
   • Correct specifications are obtained from relevant source
   • Appropriate measuring instrument is selected according to job requirements
2. Carry out measurements and calculation
   • Measuring tools are selected in line with job requirements
   • Accurate measurements are obtained to job
   • Calculation needed to complete work tasks are performed using the four basic process of addition (+), subtraction (-), multiplication (x) and division (/).
   • Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.
   • Numerical computation is self-checked and corrected for accuracy
   • Instruments are read to the limit of accuracy of the tool.
3. Maintain measuring instruments
   • Measuring instruments must kept free from corrosion
   • Measuring instruments not dropped to avoid damage
   • Measuring instruments cleaned before and after using.

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY ENGINEERING DRAWINGS.
UNIT CODE : ALT742201
UNIT DESCRIPTOR : This unit deals with identifying, interpreting and applying automotive mechanical assembly engineering manuals / specifications in accordance with requirements of the job.

1. Identify and access engineering manuals / specifications
   • Appropriate farm tools are identified according to requirement / use
   • Farm tools are checked for faults and defective tools reported in accordance with farm procedures
   • Appropriate tools are safely used according to job requirements and manufacturers conditions
2. Interpret manuals
   • Relevant sections, chapters of manuals/specifications are located in relations to the work to be conducted
   • Information and procedure in the manual are interpreted in accordance to industry practices
3. Apply information in manual
   • Manual is interpreted according to job requirements
   • Work steps are correctly identified in accordance with manufacturer specification
   • Manual data is applied according to the given task
   • All correct sequencing and adjustments are interpreted in accordance with information contained on the manual or specifications
4. Store manuals
   • Manual or specification are stored appropriately to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : APPLY APPROPRIATE SEALANT/ADHESIVE
UNIT CODE : ALT723201

This competency unit covers the selection and application of sealant/adhesives.

1. Identify appropriate Sealant/adhesive
   • Sealant/adhesive is selected in line with job requirements and manufacturer’s specification
   • Sealant/adhesive checking is performed to ensure that product is fit for use.
2. Prepare surface for Sealant/adhesive application
   • Surface materials are identified as per construction
   • Surface is cleaned and free of moisture, dust and other foreign matters to ensure maximum adhesion or seal.
3. Apply sealant/adhesive evenly
   • Sealant/adhesive is applied evenly on the surface in line with manufacturer’s specification
   • Excess sealant/adhesive is removed by sanding or scrapping
   • Tools and equipment used to apply sealant/adhesive are appropriate to job requirements
   • Safety are observed and PPE are worn in accordance with industry SOP
   • Hazards associated with the use of sealant and adhesives are identified.
4. Store/Dispose of sealant/adhesive
   • Sealant/adhesive are stored as per prescribed procedure
   • Waste are disposed as per workshop SOP

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE
UNIT CODE : ALT723205

This unit deals with inspecting and cleaning of work area including tools, equipment and facilities. Storage and checking of tools/ equipment and disposal of used materials are also incorporated in this competency

1. Inspect/clean tools and work area
   • Cleaning solvent used as per workshop/tools cleaning requirement
   • Work area is checked and cleaned
   • Wet surface/spot in work area is wiped and dried
2. Store/arrange tools and shop equipment
   • Tools/equipment are checked and stored in their respective shelves/location
   • Corresponding labels are posted and visible
   • Tools are safely secured and logged in the records
3. Dispose wastes/used lubricants
   • Containers for used lubricants are visibly labeled
   • Wastes/used lubricants are disposed as per workshop SOP
4. Report damaged tools/equipment
   • Complete inventory of tools/equipment is maintained
   • Damaged tools/equipment/facilities are identified and repair recommendation is given
   • Reports prepared has no error/discrepancy

BASIC COMPETENCIES

UNIT OF COMPETENCY : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

1. Obtain and convey workplace information
   • Specific and relevant information is accessed from appropriate sources
   • Effective questioning, active listening and speaking skills are used together and convey information
   • Appropriate medium is used to transfer information and ideas
   • Appropriate non- verbal communication is used
   • Appropriate lines of communication with supervisors and colleagues are identified and followed
   • Defined workplace procedures for the location and storage of information are used
   • Personal interaction is carried out clearly and concisely
2. Participate in workplace meetings and discussions
   • Team meetings are at ended on time
   • Own opinions are clear expressed and those of others are listened to without interruption
   • Meeting inputs are consistent with the meeting purpose and established protocols
   • Workplace interactions are conducted in a courteous manner
   • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
   • Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
   • Range of forms relating to conditions of employment are completed accurately and legibly
   • Workplace data is recorded on standard workplace forms and documents
   • Basic mathematical processes are used for routine calculations
   • Errors in recording information on forms/documents are identified and properly acted upon
   • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

1. Describe team role and scope
   • The role and objective of the team is identified from available sources of information
   • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
   • Individual role and responsibilities within the team environment are identified.
   • Roles and responsibility of other team members are identified and recognized.
   • Reporting relationships within team and external to team are identified.
3. Work as a team member
   • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
   • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
   • Observed protocols in reporting using standard operating procedures.
   • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

1. Integrate personal objectives with organizational goals
   • Personal growth and work plans are pursued towards improving the qualifications set for the profession
   • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
   • Commitment to the organization and its goal is demonstrated in the performance of duties
2. Set and meet work priorities
   • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
   • Resources are utilized efficiently and effectively to manage work priorities and commitments
   • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
   • Trainings and career opportunities are identified and availed of based on job requirements
   • Recognitions are sought/received and demonstrated as proof of career advancement
   • Licenses and/or certifications relevant to job and career are obtained and renewed

UNIT OF COMPETENCY : DEVELOP CAREER AND LIFE DECISIONSUNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

1. Identify hazards and risks
   • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
   • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
   • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
   • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
   • Effects of the hazards are determined
   • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
3. Control hazards and risks
   • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
     followed
   • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
   • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
   • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
4. Maintain OHS awareness
   • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
   • OHS personal records are completed and updated in accordance with workplace requirements

DEFINITION OF TERMS

• Automotive Vehicles – These are motor vehicles whose gross vehicle weight is equal or less than 3,500 kgs. Powered by a gas or diesel engine. It could be a passenger car or a light utility vehicle
• Automotive Electrical Assembly Technician – Refers to an all around auto electrical assembly man that can perform all electrical assembly works from assembling of electrical assemblies to mounting and installation to automotive vehicle body.
• Adhesives – Substance used to hold gasket in place during assembly. It also maintains a tight seal by filling in small irregularities on a surface and prevents gasket from shifting due to vibration.
• Point of Fit – Refers to the assembly area where parts / materials / assemblies are used or consumed
• Electronics – Electrical assemblies, circuit and system that use electronic devices such as transistors and diodes
• Hardware Parts – Refers to bolts, nuts, screws, washers and other small parts
• Catalytic Converter – Emission The control device fitted in the exhaust system of an internal combustion engine. The converter reduces the toxicity of products of combustion by catalytic re-combination
• Assembly Manuals – Reference manuals with illustration or drawings of parts/components and its direction on how they are mounted or installed on the automotive vehicle or certain assemblies.
• Quality Inspection Manuals – Reference manuals with explanation on what quality standards have to be maintained in the conduct of assembling automotive vehicle
• Work Order – A work order is a form of instruction that is broadcasted either by manual or by electronic system by preceding stations to the next stations regarding on what model sequence to produce on a timely-structured manner.
• Job Requirements – Refers to specific specifications of model/variant to be assembled.
• Standard Operation Sheet –  Is a listing of process elements arrange according to the assembly sequence for a given job requirements
• Fuel Injection – An electronic system that increases the performance ad fuel economy because it monitors engine conditions and provides the correct air/fuel mixture based on the engine’s demand. It injects fuel directly into the cylinder head enabling more precise control over the quantity used.
• Jigs/fixtures – Kind of equipment that is used for sub-assembly operations in order to meet the desired dimensions and outcome of a certain assembly.
• Crimping – Joining two pieces of metal or other malleable material by deforming one or both of them to hold the other. The bend or deformity is called the crimp. Crimping is most extensively used in metalworking. It is not generally used of specialized connectors that are designed to be deformed, but only of workpieces. Crimping is commonly used to join bullets to their cartridge cases, and for rapid but lasting electrical connectors. Because it can be a coldworking technique, crimping can also be used to form a strong bond between the workpiece and a non-metallic component. Sometimes, a similar deformity created for reasons other than forming a join may also be called a crimp
• Wiring harness – Wire harness also known as cable harness, cable assembly, wiring assembly or wiring loom; is a string of cables and/or wires which transmit informational signals or operating currents (energy). The cables are bound together by clamps, cable ties, sleeves, electrical tape, conduit, a weave of extruded string, or a combination thereof.

  Commonly utilized in automobiles, as well as construction machinery, modern-day cable harnesses provide several advantages over loose wires and cables. For example, many aircraft, automobiles and spacecraft contain many masses of wires which would stretch over several kilometers if fully extended. By binding the many wires and cables into a cable harness, the wires and cables can be better secured against the adverse effects of vibrations, abrasions, and moisture. By constricting the wires into a non-flexing bundle, usage of space is optimized, and the risk of a short is decreased. Since the installer has only one harness to install (as opposed to multiple wires), installation time is decreased and the process can be easily standardized. Binding the wires into a flame-retardant sleeve also lowers the risk of electrical fires.