Manufacture or modify wiring harnesses

This unit describes the application of the required skills and knowledge to manufacture or modify wiring harnesses including checking, replacement and labelling of the wiring harness.No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.


This unit applies to the automotive and related component manufacturing environment and involves application of skills and knowledge at a specialist level. These skills and knowledge are to be used within the scope of the person's job and authority.


Not applicable.

Elements and Performance Criteria



1. Check/test wiring harness and determine required action

1.1. Job assessment is carried out according to OHS and organisation requirements

1.2. Wiring harness and job specification is checked to determine required action

1.3. Materials and equipment for the manufacture / modification are identified and accessed

2. Manufacture wiring harness

2.1. Electrical circuit wiring diagrams are accessed and interpreted from appropriate manufacturer specifications

2.2. Harness is manufactured to job specifications using appropriate tools, techniques and materials

2.3. Harness is tested prior to placing in service and results are recorded

3. Modify wiring harness

3.1. Job information is accessed and interpreted from appropriate manufacturer specifications

3.2. Wiring harness is labelled and removed using appropriate tools and techniques

3.3. Associated components are labelled and removed and tagged for storage

3.4. Modified harness is correctly fitted to vehicle and reconnected according to manufacturer specifications and/or labels

Required Skills

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

speak clearly and directly in order to inform team members of completed wiring and modification work

apply teamwork to a range of situations

solve problems particularly in teams in order to meet performance indicators

show initiative in adapting to changing work conditions or contexts particularly when working across a variety of work areas

access, interpret and apply information on relevant organisation policies, procedures and instructions, particularly to ensure the correct testing of harnesses is carried out

manage time when planning, preparing and organising work priorities

take responsibility for organising own work priorities.

Required knowledge

relevant Occupational Health and Safety and Environmental regulations and organisation policies and procedures needed to carry out work in a manner which ensures the safety of people, equipment and the environment.

technical work documentation covering procedures, specifications, schedules and work plans or equivalent

quality system documentation covering instructions, procedures, performance indicators and review processes or equivalent

cost minimisation/waste avoidance policies, procedures and practices

environmental protection requirements relating to the disposal of waste material

established communication channels and protocols

problem identification and resolution techniques

interpreting wiring diagrams and graphic symbols

cable types/sizes, current carrying capacity and their application

circuit testing procedures (voltage drop and circuit performance)

repair and manufacture procedures

electrical termination types, applications and procedures

harness taping techniques

fault finding using aural, visual and functional assessments for damage, corrosion, wear and electrical defects

Evidence Required

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for this Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence of the following is essential:

compliance with relevant legislative, regulations, standards, codes of practice and establish safe practices and organisation policies and procedures for managing personal work priorities

maintaining a working knowledge of current work systems and practices

working and communicating effectively and positively with others involved in the work

applying, within authority, the requirements of the job or work role in relation to:

achieving production goals

achieving work quality goals

responding positively to changing work requirements

contributing effectively to cost reduction initiatives

effectively applying problem solving techniques

modify activities to cater for variations in organisation context and environment

check/test wiring harnesses

manufacture or modify wiring harnesses

removal and replacement of wiring harnesses

test wiring harnesses and locate faults

terminate electrical connections

select and use appropriate materials for manufacture/modify of wiring harnesses

complete organisation documentation - written / electronic.

Context of and specific resources for assessment

assessment of the competency should take place in a safe working environment in a passenger motor vehicle manufacturing plant or simulated environment using tools/equipment/machinery required for the production process without undue disruption to the production process

assessment is to occur under standard and authorised work practices, safety requirements and environmental constraints.

Method of assessment

A range of assessment methods should be used to assess practical skills and knowledge. The following examples are appropriate for this unit:

assessment methods must confirm consistency and accuracy of performance (over time and in a range of organisation relevant contexts) together with application of underpinning knowledge

assessment methods must be by direct observation of tasks and include questioning on underpinning knowledge to ensure its correct interpretation and application

assessment may be applied under project related conditions (real or simulated) and require evidence of process

assessment must confirm a reasonable inference that competency is able not only to be satisfied under the particular circumstance, but is able to be transferred to other circumstances.

Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording in the Performance Criteria is detailed below. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts.

OHS requirements may include:

Legislation and regulations, organisational safety policies and procedures and may include: the use of personal protective equipment and clothing, rescue services, fire fighting organisation and equipment, first aid equipment, hazard and risk control and elimination, systems covering the use of hazardous materials and substances and manual handling procedures including lifting and carrying.

Organisationrequirements may include:

access and equity principles and practices

environmental management (waste disposal, recycling and re-use guidelines)

emergency and evacuation procedures

equipment use procedures

ethical standards

legal obligations

maintenance and storage procedures

OHS requirements

organisational and site guidelines

policies and procedures relating to own role and responsibility

procedural manuals

quality assurance guidelines

quality and continuous improvement processes and standards

recording and reporting guidelines.

Materials may include:

tagging/labelling materials

cable of various types and sizes

electrical tape


fitting equipment

terminating equipment

chassis assembly


Unit sector

Technical - Electrical and Electronic

Competency Field

Manufacturing - Bus, Truck and Trailer


Not applicable.

Employability Skills

This unit contains Employability Skills.

Licensing Information

Not applicable.