ISO 45001 On-board wiring harness

　　ISO 45001 Certification and Occupational Health and Safety Management for Automotive Wiring Harnesses (Expanded Version)

　　I. Scenario-Based Adaptation and Upgrade of ISO 45001 and Automotive Wiring Harnesses

　　(I) Safety Risk Differences Among Different Types of Automotive Wiring Harnesses

　　Low-voltage wiring harnesses for passenger cars (12V/24V): The core risks are mechanical injuries (blade contact during batch cutting) and human-machine strain (intensive terminal insertion and extraction). Carpal tunnel syndrome (CTS) caused by high-frequency, repetitive work must be managed. For example, positions with terminal insertion and extraction exceeding 500 times per shift must implement a mandatory "20-minute work + 5-minute rest" rotation system.

　　New energy high-voltage wiring harnesses (300V-800V): Risks of electric shock from high-voltage arc burns and insulation breakdown are increased. Before work begins, a "triple verification" process (power off confirmation → insulation test → grounding protection) must be performed. High-voltage workshops must be divided into "red zones" (high-voltage operation areas, accessible only to certified personnel) and "yellow zones" (auxiliary preparation areas, where metal tools are prohibited).

　　Commercial vehicle heavy-duty wiring harnesses (e.g., trucks/buses): Because the harness diameter exceeds 10mm and each harness weighs over 5kg, the risk of material handling injuries (lumbar sprains, crush injuries) is significantly higher than that of passenger vehicles. A dedicated turnover rack with a lifting platform is required, and handling requires two people (each person can only carry a maximum load of 15kg).

　　(II) Cross-system Integration Practice (ISO 45001+IATF 16949+ISO 14001)

　　Quality and Safety Collaboration: Integrate the "Process FMEA" of IATF 16949 with the "Hazard Identification" of ISO 45001. For example, in the terminal crimping process, FMEA analysis is used to analyze "quality defects caused by poor crimping" while simultaneously identifying "finger pinching risks caused by crimping machine punch failures," resulting in a "Process Quality-Safety Linkage Control Table."

　　Environment and Safety Collaboration: Regarding the "VOC emissions of cleaning agents" concern of ISO 14001, chemical irritation risks to employees are simultaneously controlled. For example, when using ethanol-based cleaning agents, operations must be performed in a fume hood (air velocity ≥ 0.5 m/s), and employees must wear nitrile gloves (to prevent solvent penetration) and goggles (to prevent splashing).

　　II. Deepening the Practical Operation of Safety Control Throughout the Production Process

　　(I) "Risk-Measure-Verification" Closed Loop for Core Processes

　　Wire Cutting Process: A new and refined risk point has been added: "incorrect activation" of the automatic cutting machine (sensor failure). The upgraded control measure is the installation of a dual-activation device with "two buttons + a foot pedal," with the buttons spaced ≥ 50cm apart (to prevent single-handed operation). The verification standard is monthly simulations of sensor failure scenarios, with the activation device triggering a 100% shutdown.

　　High-Voltage Terminal Crimping Process: A new and refined risk point has been added: high-voltage leakage caused by crimping die wear. The upgraded control measure is to measure the insulation resistance with a 0.1Ω high-voltage tester after every 500 terminals crimped. The verification standard is an insulation resistance ≥ 100MΩ; otherwise, the process is immediately shut down and the die replaced.

　　Wiring harness pre-assembly process: A new risk point has been identified, specifically collisions caused by working in confined spaces (such as the instrument panel wiring harness slot). An upgraded control measure is to equip workers with retractable work mirrors with LED lighting to prevent their heads from entering gaps in the vehicle body. The verification standard is that the head must be 10 cm or greater away from metal parts during work.

　　(II) Precision Implementation of Employee Health Management

　　Job-based Health Profiles: Employees in different processes are assigned "health risk labels." For example, welding positions are assigned a "pulmonary function monitoring + fume exposure duration" label, requiring quarterly lung function testing (FEV1/FVC ≥ 80% is considered acceptable), with fume exposure limited to 4 hours per day. High-voltage positions are assigned an "electrocardiogram + insulating protective wear" label, requiring an electrocardiogram every six months (to rule out myocardial ischemia). Before each work session, workers are required to use a smart bracelet to verify the compliance of insulating shoes/gloves. Failure to meet these standards results in work authorization being blocked.

　　Psychological Safety Intervention: To address the "risk anxiety" associated with high-voltage wiring harness operations, monthly safety psychological counseling sessions are held. Through successful simulated emergency response cases, such as "Power outage within 10 seconds to rescue a high-voltage electric shock victim at a certain factory in 2023," employees' psychological stress is reduced. Employees scoring below 60 points (out of 100) on the psychological assessment are required to suspend high-voltage work.

　　III. Emergency Response and Traceability Upgrade for Typical Scenarios

　　(I) Special Emergency Plan for High-Voltage Wiring Harnesses

　　The four-step emergency response for high-voltage electric shocks: Step 1: Immediately activate the remote power-off buttons located on both the workshop control console and the work area; Step 2: Use an insulated hook with a voltage rating of 1000V or higher to separate the employee from the high-voltage terminal; Step 3: Check the employee's vital signs. If the employee is not breathing, immediately use a monthly calibrated defibrillator; Step 4: Seal the affected wiring harness and equipment, and complete a "cause analysis report" containing high-voltage circuit diagrams and sensor data within 24 hours.

　　Extended Chemical Leakage Management: When insulating agent leaks onto the ground, in addition to conventional adsorption treatment, the leak area must be tested with pH test paper (to prevent residual corrosion and slips). After treatment, exposed employees must undergo a skin swab test—clean with an alcohol pad and observe for 48 hours. A pass mark indicates no redness or swelling.

　　(II) Full-Chain Traceability Tool—"Safety Traceability Code"

　　A unique safety traceability code is generated for each batch of wiring harnesses, containing three core pieces of information: The production side records the qualifications of the operator (e.g., the validity period of the high-voltage operating license) and the safety status of the equipment (e.g., the last calibration time of the crimping machine); the employee side records the health data of the batch during production (e.g., the duration of smoke exposure for welding workers that day); and the emergency side records the "risk traceability path" of the affected batch. For example, a poor crimping of a terminal can be traced back to the chain of responsibility of "mold wear → untimely calibration → missed inspection."

　　IV. Enterprise Implementation Toolkit

　　(I) "ISO 45001 Implementation Checklist for Automotive Wiring Harnesses" (Excerpt)

　　Hazard Identification Indicator: The second-level inspection item is "Whether the high-voltage wiring harness process covers the risk of arc burns." The compliance standard is that the risk list must include "Arc energy calculation for different voltage levels."

　　Training Management Indicator: The second-level inspection item is "Certification Rate of High-Voltage Workers." The compliance standard is 100% certification, and certificates must be reviewed every two years.

　　Emergency Supplies Indicator: The second-level inspection item is "Number of Defibrillators in the High-Voltage Workshop." The compliance standard is at least one defibrillator per 500 square meters, with an emergency response time of ≤3 minutes.

　　(II) Solutions to Common Problems

　　High-voltage wiring harness workers frequently forget to perform the LOTO procedure: The solution is to install a "LOTO verification lock" on the start button of high-voltage equipment. This lock requires the insertion of an "unlock card" verified by a safety officer to start the equipment. The system automatically records the person and time of each unlock. If the LOTO procedure is not executed, the equipment will not power on.

　　Commercial vehicle wiring harnesses still require a single person to handle overweight equipment: The solution is to install a weight sensor on the turnover rack. When the load exceeds 15kg, the lifting function is automatically locked. A warning is also sent to the safety officer's mobile phone. Employees who have violated this rule three times must re-attend handling safety training.

　　V. New Industry Trend: Intelligent Safety Management

　　(I) Real-Time Risk Warning with AI Vision

　　Deploying 3D vision cameras at terminal crimping stations identifies violations such as "hands entering the safety light barrier area" and "not wearing insulating gloves" in real time. The warning response time is ≤0.5 seconds, and the equipment is automatically suspended. After implementing this technology at a certain OEM in 2024, the accident rate in the crimping process decreased by 92%. (II) Health Monitoring with Wearable Devices

　　Equip welding workers with "smart dust masks" with built-in PM2.5 sensors and heart rate monitoring modules. When smoke concentrations exceed 0.5mg/m³ or heart rate exceeds 100 beats/minute, the masks automatically emit audible and visual alarms and send notifications to team leaders, enabling "early intervention" of health risks.

　　VI. Implementation Recommendations and Subsequent Support

　　Tiered Implementation: Small and medium-sized wire harness companies can prioritize the implementation of the two core modules of "high-voltage safety + mechanical injury." Once basic management and control are stabilized, they can gradually expand into ergonomics and psychological safety.

　　Customized Requirements: If a specific safety plan for a particular type of wire harness (such as high-voltage wiring harnesses for hydrogen vehicles) is required, or if supporting tools such as the "Emergency Drill Script Template" and "Job Health Risk Assessment Form" are required, further details of the requirements can be provided to provide more targeted support.