Wire Harness Inspection Checklist A-620

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13 critical items still open - these are the highest-risk gaps.

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Materials and preparation

Drawing and build revision match the travelerCRITICALWire, connectors, contacts and terminals match the BOM and approved sourcesCRITICALLot or date codes recorded for wire, contacts and connectorsCRITICALTools calibrated and crimp tooling matched to contact and wire gaugeCRITICALWire stripped without nicks, cut strands or damaged insulationWork area is clean, ESD controls are in place where requiredTinned or untinned conductors handled as the drawing requires

Crimping and terminals

Crimp height or pull test verified at setup and at the frequency in the work instructionCRITICALConductor strands visible in the inspection window, none cut or folded backInsulation support crimp holds the insulation without cutting throughNo bent, damaged or contaminated contactsContacts fully seated and retention verified by light tugCorrect contact inserted into each cavity per the wiring listCRITICAL

Soldering, shielding and termination

Solder joints wet properly and conductor outline visible per the class requirementCRITICALNo solder wicking under insulation that stiffens the wireShield terminations meet the drawing: pigtail, solder sleeve or backshell as specifiedHeat shrink and solder sleeves fully recovered, no scorchingInsulation clearance gap within the drawing limitStrain relief fitted and seated

Routing, lacing and marking

Bend radius meets the minimum for the cable typeTies, lacing or clamps spaced and tensioned as the drawing statesNo sharp edges or pinch points on the routeWire and cable markings legible, durable and in the correct positionCRITICALConnector keying and polarity correctLabels carry part number, revision and serial number as requiredCRITICAL

Test and release

Continuity and isolation tested against the wiring listCRITICALHigh-potential or insulation resistance test performed if specifiedCRITICALTest equipment calibration current and results recorded with serial numberCRITICALVisual final inspection performed to the customer class (1, 2 or 3)Nonconformances documented and dispositioned before releaseCRITICALPackaging protects connectors and prevents damage in shipmentRecords retained per contract retention requirements

Mark every item. Any unchecked critical item should stop release until corrected or dispositioned. This checklist follows topics covered by IPC/WHMA-A-620 and is not a copy of the standard, so use the current standard and your drawing for acceptance criteria.

Keep inspection records searchable

Optional: a short look at how inspection results could be analyzed alongside ERP data.

Optional. The tool and every export work without this. No spam.

How to use the checklist

Print or fill the checklist for each harness or each lot, depending on your work instruction. Go through the groups in order: materials, crimps, soldering, routing, test. Mark critical items first, since they stop release when missed. Export to PDF or Excel and attach it to the build record with the serial number. If your customer specifies a class (1, 2 or 3), record it at the top and apply the matching criteria from the standard to every visual check.

What the standard covers

A-620 is an acceptance standard rather than a design guide. It describes target, acceptable and defect conditions for items such as crimped terminations, soldered terminations, wire preparation, insulation, wire dress, marking, and shielding. Class 3 is for high-reliability products, including most defense and aerospace work. The checklist reflects those topics, but the drawing and customer specification may add stricter limits or other test steps.

Class 1: general electronic products
Class 2: dedicated service electronic products
Class 3: high-performance, harsh environment products
Customer drawing overrides general guidance

Common mistakes

Typical problems are crimping with the wrong tool die for the wire gauge, skipping pull tests at changeover, placing a contact in the wrong cavity, and forgetting to record lot codes for traceability. Another common issue is accepting a harness on continuity alone, missing intermittent faults that show up under flex. Keep inspector stamps controlled, train to the current revision and record rework so repeated defects trigger corrective action.

Frequently Asked Questions

Is this checklist a substitute for IPC/WHMA-A-620?

No. It lists the topics to check. Acceptance criteria, photos and class-specific limits are in the standard, which you need to license and train to. Use this as a build aid alongside your drawing and the current standard.

Which class should I build to?

Use the class in your purchase order or drawing. Defense and aerospace work is commonly Class 3. If no class is stated, ask the customer, and do not assume. The class changes what counts as an acceptable condition.

How often should crimp height be checked?

Follow your work instruction and the tooling maker. Many shops check at setup, after tool change and at set intervals during a run. The checklist asks you to confirm that your defined frequency was followed.

Can I add my own items?

Yes. After exporting to Excel you can add rows for customer-specific tests, special marking or serialization rules. Keep a controlled revision of the checklist so builds can be traced to the version used.

Netray can help turn checklist results into searchable quality data in your ERP. Ask us if you want build records analyzed privately on your own hardware.

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Wire Harness Build and Inspection Checklist (IPC/WHMA-A-620)