Up to 70 percent faster: EasyWiring Board now features integrated testing

In aerospace and industrial environments, wiring harness manufacturers often face a demanding combination of small production volumes, many variants, and strict documentation requirements. Prototype development, repairs, and low-volume production all require a flexible production setup while ensuring that every step remains controlled and traceable. At the same time, quality must meet the very highest standards, since even the smallest errors in wire processing can lead to extensive rework, delays, and additional costs.

The risk of errors is particularly high when wire harnesses contain many conductors, variants, or similar connectors, making precise wire identification before assembly crucial. Before assembly begins, each individual wire must be clearly identified and assigned to the correct connection point, forming the basis for an efficient, repeatable, and error-free production process.

This is exactly where Komax’s software-controlled EasyWiring Board steps in. Combined with the Cirris 8100 low-voltage tester, it creates a direct digital link between design, assembly, and testing. Instead of relying on physical boards or paper-based instructions, operators are guided directly on the EasyWiring board, while continuity testing can be performed during the production process.

Digital guidance and testing on the board
The workflow with EasyWiring and the Cirris 8100 tester is clearly guided from the start. First, the operator places the fixtures in the color-coded positions displayed on the digital board. During wire routing, each wire end is connected to the appropriate accessory. The system automatically identifies the wires and highlights their path. For manual assembly, EasyWiring also displays the second connection point so that stripping, crimping, and inserting can be carried out accurately. This reduces the need for manual information searches and supports operators at every step of the process.

As soon as the connectors are plugged into the Cirris 8100 tester, a low-voltage continuity test of the entire wire harness can be performed at any point during production. The tester can be seamlessly integrated into any EasyWiring board, and each unit provides 256 test points, which can be expanded to up to 2,048 points. In addition to automated continuity testing, it also enables passive component testing for resistors, diodes, and capacitors.

At the end of the process, cable ties, sleeves, or tubes are placed at the marked positions. The result is a structured workflow in which assembly and testing are no longer treated as separate production steps, but as part of one integrated process, making production easier to manage. Especially in environments with frequent product changes and a high number of variants.

Up to 70 percent faster
Depending on the application, combining EasyWiring with the Cirris 8100 tester can result in time savings of 40 to 70 percent. Critical factors here include shorter setup times, automatic wire probing, guided operation, and continuity testing directly on the board. This reduces the effort required to prepare physical boards and limits interruptions caused by manual checks or separate testing procedures. Errors can be detected earlier in the process, before they lead to extensive rework. At the same time, digital guidance supports faster operator training and helps ensure that assembly steps are performed consistently.

For wire harness manufacturers in low-volume, high-mix production environments, the combination of EasyWiring and the Cirris 8100 tester has created a solution that goes far beyond a traditional board. It combines guided assembly, rapid wire assignment, and in-process testing in a single system, supporting production processes that must remain flexible, transparent, and cost-effective despite a high degree of product variety.