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NADCAP Aerospace Electrical Harness Assembly Audit Checklist

A comprehensive audit checklist for electrical harness assembly operations in aerospace manufacturing, ensuring compliance with NADCAP standards and optimizing quality control in the production of reliable and safe wiring interconnect systems for aerospace applications.

NADCAP Aerospace Electrical Harness Assembly Audit Checklist
by: audit-now
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About This Checklist

The NADCAP Aerospace Electrical Harness Assembly Audit Checklist is a vital tool for aerospace and defense manufacturers specializing in electrical wiring interconnect systems (EWIS). This comprehensive checklist addresses key aspects of harness assembly, including wire selection, crimping, soldering, connector assembly, shielding, and testing procedures. By implementing this checklist, organizations can effectively evaluate their electrical harness manufacturing operations, ensure compliance with stringent aerospace standards, and maintain the highest level of quality in producing reliable and safe wiring systems. Regular use of this checklist helps companies streamline their audit preparation, optimize assembly processes, and enhance the overall performance and durability of aerospace electrical harnesses.

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Industry

Aerospace and Defense

Standard

NADCAP

Workspaces

Electrical Harness Assembly Facility

Occupations

Electrical Harness Assembler
Avionics Systems Engineer
Quality Assurance Technician
NADCAP Auditor
Aerospace Electrical Engineer

Electrical Harness Compliance Audit

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1
Describe the harness testing procedures implemented at the facility.

Provide a brief overview of the testing procedures used.

To assess the effectiveness and thoroughness of testing procedures.
2
Is the connector assembly compliant with the specified standards?

Select compliance status.

To verify that the assembly processes align with compliance standards.
3
What is the quality score of the aircraft cable crimping?

Enter a score from 1 to 5.

To quantify the quality of crimping and identify any areas for improvement.
Min: 1
Target: 5
Max: 5
4
Is the wire processing performed in accordance with aerospace soldering standards?

Select compliance status.

To ensure that the wire processing meets industry standards and maintains quality control.
5
Describe the incident reporting procedures in place for electrical safety.

Provide details on the incident reporting procedures.

To assess how effectively incidents are reported and managed.
6
What is the current rating of the electrical safety training program?

Rate the training program from 1 to 5.

To evaluate the effectiveness of the training program provided to personnel.

1

2

3

4

5

7
Is the EWIS quality control process being followed correctly?

Select the appropriate compliance status.

To assess adherence to quality control measures in the EWIS process.
8
Is all necessary safety equipment available and functional?

Confirm the availability of safety equipment.

To ensure that safety equipment is ready for use in electrical harness assembly operations.
9
Describe the defect reporting mechanism for wiring issues.

Provide details on the defect reporting process.

To evaluate how defects are reported and managed within the facility.
10
Is all relevant cabling documentation available and up to date?

Confirm the availability of cabling documentation.

To ensure that proper documentation is accessible for reference and compliance.
11
How often are cable inspections conducted?

Enter the frequency of inspections (in months).

To determine the frequency of inspections for maintaining wiring integrity.
Min: 1
Target: 6
Max: 12
12
Does the wiring integrity meet the aerospace standards?

Select the compliance status of the wiring integrity.

To ensure that wiring integrity complies with safety and operational standards.
13
Provide an overview of the harness testing procedures followed in the facility.

Describe the harness testing procedures in detail.

To assess the thoroughness and effectiveness of the testing procedures.
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14
Are all test results documented and accessible?

Confirm the availability of documented test results.

To ensure that all test results are properly recorded for verification and compliance.
15
What is the maximum load capacity tested during harness trials?

Enter the maximum test load capacity (in pounds).

To verify that the load capacity meets or exceeds the required standards.
Min: 50
Target: 150
Max: 200
16
Is the testing equipment calibrated per aerospace standards?

Select the calibration status of the testing equipment.

To ensure that testing equipment is functioning correctly and providing accurate results.
17
Describe the quality control inspection methods used for harness assemblies.

Provide details on the quality control inspection procedures.

To evaluate the effectiveness of quality control measures in place.
18
Are all safety protocols being followed in the assembly area?

Confirm adherence to safety protocols.

To ensure that workplace safety standards are maintained during assembly operations.
19
What is the current defect rate percentage in harness assemblies?

Enter the defect rate percentage.

To quantify the quality of the harness assemblies and identify areas for improvement.
Min: 0
Target: 2
Max: 10
20
Is the harness assembly process compliant with NADCAP standards?

Select the compliance status of the assembly process.

To ensure adherence to NADCAP accreditation requirements for harness assembly.

FAQs

The checklist addresses wire gauge selection, insulation type verification, temperature rating compliance, and traceability of aerospace-grade wires and cables.

It includes items on crimp tool calibration, proper die selection, crimp height measurements, pull testing procedures, and visual inspection criteria for crimped connections.

The checklist covers soldering iron temperature control, flux selection and application, proper soldering techniques, and inspection criteria for soldered joints in accordance with aerospace standards.

It includes sections on connector pin insertion verification, backshell tightening procedures, strain relief methods, and sealing techniques for environmental protection.

The checklist addresses continuity testing, insulation resistance measurements, dielectric withstand voltage testing, environmental stress screening, and final inspection procedures for completed harnesses.

Benefits

Ensures compliance with NADCAP requirements for electrical harness assembly in aerospace

Improves consistency and quality of critical aerospace wiring systems

Helps prevent electrical failures and safety hazards due to improper harness assembly

Enhances process control and documentation in wire processing and connector assembly

Facilitates continuous improvement in harness manufacturing techniques and testing procedures