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I stopped shotgunning wires and started ringing them out one at a time, and my rework rate dropped to almost nothing
For years I was the guy who pulled a whole bundle, pinned the connectors, and then chased down the two wires I crossed somewhere in the middle of a 60 pin harness. I figured it was faster to just build the thing and fix whatever squawked on the bench. Last spring I had a job on a King Air panel where I spent nine hours hunting a single swapped wire behind the pedestal, and the customer was standing right there watching me pull the whole thing back apart. That was the day I changed my mind. Now I ring out every wire with a meter before I even put a pin in it, one at a time, and I keep a little notebook with the pin numbers ticked off as I go. It feels slow when you are doing it, like you are wasting time standing there with a probe, but I have not had a single crossed wire in eight months and my rework went from maybe one job in five down to zero. The old timers who taught me said to build first and check later, and I believed them for way too long. Curious what the rest of you do, do you continuity check as you pin or do you trust the build and test at the end?
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hall.quinn3d ago
Standing there ringing out every wire one at a time sounds great until you're on the clock and the boss is asking why a 40 hour job turned into 60. I've built plenty of harnesses the fast way and the squawk on the bench usually traces back pretty quick once you got a meter and a print in front of you. Sounds like you just had one bad night on that King Air and rewrote your whole religion over it.
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