Quality means Complete Customer Satisfaction

YAZAKI has multiple simulation tools and we process our investigative research through virtual design and digital factory concepts, which results in the following benefits:

• Reduced response time for design changes
• Fewer physical prototypes through ‚Real life’ Harness simulation and digital prototyping
• Reduced time to market by early design verification
• Feasibility study and integrated manufacturing
• Reliability and intensified Quality assurance

R&D pacesetting design

YAZAKI’s globally recognised standards in its core competencies are realised through the virtual design and digital factory work in our R&D design centres. The following value chain process areas are included:

Architecture optimisation

An analysis of vehicle layout, partitioning and system function is undertaken, enabling easy comparison of different scenarios. Through the simulation of these scenarios, any necessary changes can be immediately included in the Electrical Distribution System (EDS). This results in the complete optimisation of the EDS and a unique advantage for the customer.

3-D Design

Realistic harness design requires consideration of minimum bending radius and gravity. Within this digital process, it is possible to check the mechanical routing of the wiring harness. Through a tolerance analysis, any possible conditions which might lead to noise or rattle in the car can be found and resolved. As with architecture optimisation, 3-D design simulation results in the immediate identification of any necessary design corrections and their inclusion from the earliest possible stage of production.

Production Simulation

Feasibility and an optimised jig board layout for production are important. As a manufacturing company with a long tradition in the production of wiring harnesses, we know how important a link between design and production can be. The jig boards necessary for production can be virtually checked for non-feasibility, sometimes caused by lack of space for example. This guarantees smooth manufacturing, as the findings of the product simulation analysis are incorporated into the production process.

Installation Simulation

In the past potential issues while installing a wiring harness in the car couldn’t be identified in early design phases. Now it’s possible – By the use of this simulation, the installation can be checked and the harness verified in order to avoid mismatch and assembly issues. Necessary modifications, e.g. clip positioning or length adaptation, without building a prototype are possible. and ensure significant savings in both time and costs.

Bending Simulation

Bending simulations are held, in order to predict the wiring harness’ moving parts lifetime. This involves an exposure to high levels of stress to ensure the reliability of the system. This tool has been introduced to the development chain in order to facilitate the analysis of wire harnesses in a simulated course of movements. This means any possible changes can be included early on in the design process.

YAZAKI ‘Right at First time’ approach – It’s your quality, reliability and time advantage.

YAZAKI follows a strict zero-defect policy, with the ultimate goal constantly in mind:

Constant process perfection throughout the supply chain.

The process begins in the early concept design phase. The manufacturing engineers take part in early design and development decision discussions to ensure the utmost in your product quality results and feasibility.

There is an increased market demand worldwide for shortening the development lead time. Yazaki has multiple simulation tools for design directions and process investigation through digital factory concepts.

Right on target - every time

The industrialisation phase is similar but still different for each project; a unique set of activities that produce deliverables within specified time, cost and quality constraints. Our target is:

To translate the customers’ request into a finished product feasible for mass production.

New project requests are structured and processed using an internal tool which was developed and customised for YAZAKI’s needs. It is continuously refined to meet the various, ever-fluctuating requirements of our customers. This tool is based on the Advanced Product Quality Planning (APQP) system, developed in the 1980’s in the USA, as a structured method to define and follow up on all aspects of design and development up to production.

Exemplary project coordination

At YAZAKI, the entire industrialisation process is led by Project Managers who coordinate all activities - from the tool’s kick-off until the end of the project. These managers are known for their ability to coordinate resources, control the project timing and budget and evaluate the potential risks throughout the project to achieve successful results.

Skilful staff for your project team

YAZAKI has very high requirements for its employees. Those responsible have an engineering background with specific individual understandings of moulding and stamping technologies, and extensive teamwork experience working with toolmakers.

YAZAKI and our partners share information daily with one another to deliver a product that perfectly complies with YAZAKI’s stringent requirements.

Our most important asset - for your most important results

During the course of a project, the project management team is probably the most valuable part of the YAZAKI organisation. In order to motivate and ensure team competitiveness, YAZAKI’s project managers are continuously trained both internally and externally in new technologies, processes, tooling techniques and other important aspects.

When introducing technologies from other markets, YAZAKI Europe promotes learning by giving focused training to our project management team, as well as gaining assistance from affiliates that have experience with the technology.