on-demand webinar

Modernizing wire harness manufacturing in aerospace

How the use of a digital twin is transforming classic production preparation methods

Estimated Watching Time: 35 minutes


A woman works on the wire harness of an aircraft

Industry trends are pushing companies in the aerospace and defense sector to make changes. This is related to the pressure to reduce the program cost and schedule, the increasing complexity of aircraft, supply chain bottlenecks and a shrinking workforce. The combination of these trends is causing exponential increases in the risk and costs associated with these products. This leads companies to constantly look for new solutions to address these changes.

To overcome these challenges, companies are undergoing a digital transformation. Capital™ software, part of the Siemens Xcelerator portfolio, provides a complete model-based solution for E/E system development, supported by a virtual twin. The end-to-end process covers the entire product lifecycle from early design to production and service domains, accelerating ramp-up and ensuring traceability at every stage.

But what does this mean for wire harness manufacturing?

Efficient wire harness manufacturing with a digital twin

Wire harness manufacturers must constantly balance quality, delivery and cost targets while managing complexity and reducing these risks. As it is impossible to eliminate risk, companies must focus on managing it effectively.

Traditional wire harness manufacturing methods rely heavily on manual processes. The process typically consists of three basic steps: cutting the cables, shaping the wire harness on the formboard and assembling the connectors. An element often underestimated in creating an efficient manufacturing process is a correctly designed formboard. Its proper design enables operators to work productively and manufacture a wire harness right the first time.

Classical MCAD drawing methods in isolation from wire harness data make the creation process long and prone to many errors. Making changes is cumbersome and does not guarantee their correct management, with the inappropriate selection of components increasing the cost of implementation.

In this webinar, you will find out how to use the digital twin to create a cost-effective and ergonomic formboard.

Meet the speaker

Siemens Digital Industries Software

Bartosz Czarnecki

Product Manager and Leader of Harness Manufacturing

Bartosz Czarnecki’s entire 17-year professional life has been dedicated to electrical harnesses. Since the very beginning of his career, he has been employed in the aerospace industry, where he has held various positions, starting with electrical operator, then process engineer and on to production engineering manager. All of these roles were in the area of electrical harnesses. In addition to the aerospace industry, part of his career has been dedicated to the space industry. During that time, he focused not only on production engineering, manufacturing and the testing of electrical harnesses, but he also, due to the specificity of the area, worked on their design. He is an engineer with master’s degree from Technical University of Radom (Poland), where he graduated in electrotechnics.