ASHLEY DODGE

Problem:  Improve a current wire harness to prevent wire damage during light bar rotation

Action: 

• Ran test analyzing root cause of wire failure

  • After manual light bar rotation testing, it was noticed that the wires near the connector would sit flush to the endplate of the light fixture.  When rotated, this would cause abrasion and eventually exposed wire.

• The connector was replaced to change the orientation of the wires exiting the connector which prevented abrasion.

Results:  After additional rotation testing, it was determined that the light bars would be able to withstand over 1000 rotations with the new connector.  After updating wire drawings, this improvement was then put into production.