Cable and Wire Harness Build Inspection Record Template
Harness failures are frequently crimp or pin placement problems that pass a quick glance. This record puts crimp, continuity, insulation and labeling checks on one page so every harness leaves with evidence.
Fill in
Cable and Wire Harness Build Inspection Record Template
Harness Build Inspection Record
Company: Harbor Electronics Inc. Harness: W-210450-01 Rev B Work order: WO-559002 Quantity: 12 Date: 2026-10-20 Workmanship class: Class 3
Tools and Test Setup
Crimp tool: Daniels AFM8, cal due 2027-01-15 Test equipment: Cirris continuity tester, hipot tester HP-02 Insulation test: 500 VDC, 1 minute, no breakdown
Inspection Points
| Check | Requirement | Result | Initials |
|---|---|---|---|
| Wire gauge and color per drawing | Matches wire list | ||
| Strip length and conductor damage | No nicked or cut strands beyond limit | ||
| Crimp height or pull test | Per crimp spec for contact and wire | ||
| Connector pin and position | Per wiring diagram | ||
| Continuity and shorts | 100 percent tested | ||
| Insulation resistance or hipot | Per test procedure | ||
| Labels and marking | Legible, correct, secure | ||
| Dress, routing, strain relief | Per drawing |
Comments
All 12 harnesses passed continuity and insulation tests. Label legibility verified on all units.
Approvals
Acceptance limits come from your drawing, the connector or contact manufacturer's crimp specification and the workmanship standard. Edit the check list to match your drawing.
Capture test data in the ERP
Optional review of pushing tester results to work orders.
Optional. The tool and every export work without this. No spam.
How to use it
Fill in the harness number, revision and work order, then print or export the form to Word to adjust the inspection table for the drawing. One form can cover a lot if tests are 100 percent and you list exceptions in comments. Record the crimp tool and its calibration date because crimp quality depends on the tool. Sign the form only after the final visual and test results are in.
Standards behind it
IPC/WHMA-A-620 is the common acceptance standard for cable and wire harness assemblies and defines three classes similar to IPC-A-610. Contact crimps are controlled by the crimp specification for the contact, such as military or manufacturer crimp height and pull force tables. Continuity testing should confirm every circuit and reveal shorts, while insulation or dielectric tests are chosen to match the wire rating.
Common mistakes
Crimp tools out of calibration, wrong contact and wire pairings and missing strain relief are the top reasons for field returns. Another is relying on sample continuity testing when the drawing demands 100 percent. Record the revision of the wire list used, since a mid-run drawing change is hard to reconstruct later. Keep the tester output file with the record when the tester can export one.
Frequently Asked Questions
What is IPC/WHMA-A-620?
It is an industry standard for requirements and acceptance of cable and wire harness assemblies. It covers wire preparation, crimping, soldering, connectors, marking and more, with three product classes.
Do I need to pull test every crimp?
Usually not. Most shops verify crimp height or do periodic pull tests at setup and at intervals defined in the work instruction. Follow the crimp specification and your quality plan.
Is hipot testing always required?
No. It depends on the drawing, voltage rating and customer requirement. When required, record the voltage, time and result on the form.
How should failed harnesses be handled?
Tag them, raise an NCR and apply rework or scrap per your procedure. Reworked harnesses should be retested at 100 percent.
Netray can help link harness test results to the work order and serial number in your ERP or MES.
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