客户发来一张图纸，到收到成品线束，中间要经过12道工序。了解全流程，您就知道报价里每一分钱花在哪、交期卡在哪，也更能识别供应商的成色。
From your drawing to finished harness, 12 steps stand in between. Knowing them tells you where cost and lead time live — and how to judge a supplier.
工序1-3：来料检验 → 裁线 → 剥皮Steps 1-3: IQC, cutting, stripping
线材、端子、连接器来料检验（核对UL印字/批次/外观）。全自动裁线机按图纸裁线（如成品1000±30mm对应裁线1010mm，留出端子占用余量），剥皮机剥头并控制剥皮长度与不伤芯线。
IQC verifies UL markings and lots. Auto cutters cut to length (1010mm cut for 1000±30mm finished), strippers strip without nicking strands.
工序4-6：压接 → 插壳 → 焊接Steps 4-6: crimping, insertion, soldering
端子机压接（首件必做截面分析+拉力确认），压好端子的线插入连接器塑壳并锁定；需要焊接的点位（PCB针、传感线）人工烙铁或自动焊。这一段是品质核心区。
Crimping with first-article cross-sections, terminal insertion into housings, and soldering where required. This is the quality core zone.
工序7-9：绞线/屏蔽加工 → 注塑/热缩 → 组装分支Steps 7-9: twisting/shielding, molding/shrink, assembly
按图纸双绞、包铝箔、加编织层；插头注塑（防水/加固）或套热缩管；多分支线束在工装板上组装定位、缠胶带/扎线带固定走向。
Twisting, foil and braid application; injection molding or heat shrink; branch assembly on fixture boards with tape and ties.
工序10-12：电测 → 外观检 → 包装出货Steps 10-12: electrical test, visual check, packing
导通/耐压/错位全检（治具逐点核对），外观全检（标签、色序、胶带、损伤），最后按客户要求盘绕、装袋、贴批次标签出货。关键工序全检、其余按AQL抽检。
100% continuity/withstand/mis-assignment testing with fixtures, full visual check, then coiled packing with lot labels. Key processes 100%, others by AQL.
交期构成参考Where the lead time goes
打样：线材端子齐料后3-7天；量产：视批量1-4周。最长瓶颈通常是特殊线材/进口连接器的采购周期，定制前先确认物料交期，可避免整体延期。
Sampling: 3-7 days after materials ready; production: 1-4 weeks by volume. The bottleneck is usually special wire or imported connectors — confirm material lead times first.