There are a few options any company can use to manage wires and wire harnesses.  The list below is ordered by user friendliness from least to most. While not comprehensive, it does include the most common approaches possible.

1. Manual/External Documentation - This method allows users to enter the consolidated information about each assembly (i.e. total length of each type of wire, all connectors, etc) as a BoM and let MRP handle the material flow. However, it requires external documentation for processing each wire and assembling the harness. This method is flexible, customizable, and will work with nearly any ERP system. However, it is very manual, not very efficient, and doesn't work well at high volumes and complexities.
   
   
2. In System Static Documentation - This is similar to the first method but allows users to load details about the assembly within the system. This allows for more efficient distribution and better documentation control. However, it is still not very efficient and requires additional systems or processes for preparing each wire.
   
   
3. Custom External Applications - A custom application to enter and manage individual wires can add all the required functionality and may be able to validate information to ensure accuracy. Although this contains the required information, it isn't integrated and would require additional security controls and add an extra step for entering and updating the information. However, it may be possible to create custom reports to combine ERP and custom application information into a single report for production purposes.
   
   
4. User Defined Fields - If the system will allow, user can utilize user defined fields (UDF) for store and processing information on each wire. With sufficient fields, users will be able to store wire gauge, length, termination and strip details. If this is not all in a single text field, the information can be exported for additional processing at the wire cutting machines.
   
   
5. Full Feature Implementation - If the system will allow it, this method is the most efficient. It will allow for storing all pertinent information about each wire without creating subassmblies. It will allow exporting for processing by the cutting machines. And, it potentially could help in grouping similar wires by gauge, color, length, termination, etc. This is the most automated and ideal.
   

ManEx has current and planned features to make wire harness processing as easy as possible.

1. BoM Item Notes - This is an open text field that allows users to add details about the line item. This can be a great place to add details for production. 
   
   

   While this does not automatically translate into combined cut cards for the cutting machines, it will automatically provide assembly details to production through the BoM.

   Below is an example of how this could look if several BoM line items have wires setup.

2. Related Documentation - Excel files and other related documentation can be created outside ManEx and attached in ManEx.  Users can attach* these documents to the internal part number and/or to the shop floor tracking setup.  This provides a central location to manage and control the documents and automatic electronic distribution of the documents to production.  However, this still requires external processing to combine like wires and increase operational efficiencies at the cutting machines.
   
   
3. External Applications - As an interim solution until the ManEx upgrade is complete, and to fully test the concept. We have created an access database partially integrated with ManEx that allows users to:
   
   
   1. Define wires for each wire harness assembly. 
      The current design has several standard fields, but users can add more fields to the tables, form, and reports.
      
      
   2. View those wires in a production bill of material. 
      By selecting the assembly and part number, wires are automatically added to the appropriate item on the Harness BoM.
      
      
   3. Combine like wires across assemblies and Work Orders for more efficient processing through the cutting machines.
      Users select the Work Orders they want to process and the report lists all wires grouped by part number and sorted by length, then Termination A, then Termination B.  This information can be exported to excel.  Additionally, users can modify the report to group and sort by other information.
      
   
   The database and Crystal Reports validate the Assemblies, Part Numbers, BoM Line Items, and Work Orders through ManEx to eliminate the duplication of information. We will make the application and reports available to all interested readers willing to provide feedback.

• BoM Module Modification - This will add an additional tab to the BOM module for wire harness processing. All the standard fields required for completing wire harnesses would be available. This allows users to quickly load pertinent information. Then, users would be able to export to the cutting machines and do additional analysis and processing as needed. 
  
  Users interested in this feature should submit a list of the fields (name, length, type, etc) typically required for creating wires so that we can include them in the plan.

While these methods are not the only solutions, they do seem to be the most universally applicable and acceptable.  They also add some efficiencies to the process.  If you are interested in discussing these ideas in greater detail, please let me know.