Review of Current Status and Future Directions for Collaborative and Semi-Automated Automotive Wire Harnesses Assembly
Paper in proceeding, 2023

Wire harnesses are vital for any modern automotive vehicle. They control the basic functions in a vehicle, for example, windshield wipers and critical functions such as sensors, cameras, and autopilot functions. Thus, the quality of wire harness assembly is highly important. Today, wire harnesses are usually assembled manually, which creates unergonomic and tedious working conditions for operators. Traditional and collaborative industrial robots have been identified as possible solutions to overcome challenges faced by operators in this type of assembly. The international research community has proposed many solutions for automating the assembly of wire harnesses in automotive vehicles but despite these solutions, the industry has not been able to adopt a method to automate this assembly process fully or partially. This paper presents a review of findings on robot-assisted wire harness assembly processes based on a systematic literature review. Specifically, the assembly of wire harnesses in Electric Vehicles (EVs). The state-of-the-art review focuses on solutions to improve unergonomic work situations and ensure the quality of assembly operations. Best practices and reasons for the lack of extensive implementation in automotive final assembly systems are described. Further, the paper presents suggestions based on success stories where the automation of the wire harness assembly in automotive vehicles has been realised by leveraging human-centred automation solutions. Based on the findings, this paper identifies the research for future study. The findings also indicate that there is already technology that can support the automation of wire harness assembly processes in EVs but it is crucial to identify the human aspects and the role of humans in the assembly of wire harness assembly process.


Electric Vehicles

Collaborative Robots

Assembly Operator

Automotive Wire Harnesses


Omkar Salunkhe

Chalmers, Industrial and Materials Science, Production Systems

Walter Quadrini

Polytechnic University of Milan

Hao Wang

Chalmers, Industrial and Materials Science, Production Systems

Johan Stahre

Chalmers, Industrial and Materials Science, Production Systems

David Romero

Monterrey Institute of Technology and Higher Education

Luca Fumagalli

Polytechnic University of Milan

Dan Lämkull

University of Skövde


Procedia CIRP

22128271 (ISSN)

Vol. 120 696-701

56th CIRP International Conference on Manufacturing Systems, CIRP CMS 2023
Cape Town, South Africa,

EWASS Empowering Human Workers for Assembly of Wire Harnesses

VINNOVA (2022-01279), 2022-07-01 -- 2025-05-31.

Subject Categories

Mechanical Engineering

Electrical Engineering, Electronic Engineering, Information Engineering



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