Overview Mssl

8/4/2019 Overview Mssl

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Overview about the company

MothersonSumi Systems Limited (MSSL) is the flagship company of the SamvardhanaMotherson

Group and was established in 1986. It is a joint venture between SamvardhanaMotherson Groupand Sumitomo Wiring Systems (Japan). MSSL is a focused, dynamic and progressive company

providing customers with innovative and value-added products, services and solutions.

The Company is listed at the stock exchanges since 1993. The recent acquisition of mirrorbusiness from Visiocorp (now renamed as SamvardhanaMothersonReflectec) has helped MSSL

evolve as one of the worlds leading automotive mirror manufacturer. The Company is Indiaslargest manufacturer of automotive wiring harnesses and mirrors for passenger cars. It is also aleading supplier of plastic components and modules to the automotive industry.

MSSL facility in Noida MSSL facility in Bangalore

Over the years MSSL has collaborated with global technology leaders and has further leveragedits competency in existing areas to create products fulfilling the technical needs of its customers.MSSL and its joint ventures have invested in state-of-the-art technologies and infrastructure to

ensure superior efficiencies & total customer satisfaction.

MSSL is strengthening its position as a globally preferred solution provider by offering end-to-endsolutions encompassing designing from basic data to prototyping, tooling, molding, assembly and

integrated modules. The ability to provide this end-to-end solution in each product category andcombine these solutions in the form of full system solutions has enabled the Company to evolve

as a preferred supplier. These solutions are supported by the flexibility to supply from any of thealternative manufacturing bases and logistic models best suited to customer requirements.

MSSL has developed a network of manufacturing bases, design centers, logistics centers,

marketing support and sourcing hubs across a diversified geographical base. MSSL has presencein 21 countries which includes India (Noida , Gurgaon, Manesar, Faridabad , Pune, Bengaluru,Chennai, Kandla, Lucknow&Puducherry), UAE., Sri Lanka, Singapore, China, South Korea, Japan,Germany, UK., Czech Republic, Austria, Hungary, Italy, Spain, France, Ireland, U.S.A, Mexico,

South Africa, Australia & Mauritius to provide timely and quality delivery its customers worldwide.MSSL has manufacturing bases across five continents - Asia, Europe, North America, Africa&Australia to support its customers. MSSLs diverse global customer base comprises of almost allleading automobile manufacturers globally.


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Product RangeIt has been MSSLs endeavour to constantly add new products in its product line with theobjective of emerging as a single-service interface for multiple customer needs. MSSL has 9 JVpartners with over 14 collaborations. The Company has collaborated with technology leaders intheir respective fields to bring relevant technologies for the products required by its customers.

MSSLs diversity of product range coupled with the depth within each product portfolio, hashelped the company garner leadership in its area of operations.

The product range of the company along with its subsidiaries and joint ventures includes:

Automotive Rear View Mirrors

Wiring Harnesses

Wires

Seals

Grommets

Tubes

Fuse Boxes

Injection Molded Products

Blow Molded Products

Liquid Silicone Rubber Molded Components

Injection Molding Tools

Extruded Rubber Products

Precision Machined Metal Components

Modules

IP/ Cockpit

Door Trims

Bumpers

Air intake manifolds

Air filter systems

HVAC Systems

Waste Recycling System


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History


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1975

Motherson was founded

1977

First Cable factory started

1983

Technical agreement with Tokai Electric Co. (Now

Sumitomo Wiring Systems - Japan) for Wiring Harness

1986

JV with Sumitomo Wiring Systems Japan

1989

Injection Molding

1992

Cutting Tool Manufacturing

1994

Tool Room for small and Medium sized Molds (upto 650

Tons)

1995

Cockpit Assemblies

Automotive Mirrors

1997

Blow Molding


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1998

Rubber Injection Molding

1999

First Overseas office established (Austria)

2000

IT and Design Company

Representetive Office at Singapore

2001

Liquid Silicon Rubber Injection molding

Machined Metal Components

2002

Wiring Harness manufacturing at Sharjah

Design Centre at Ireland

2003

Offices in USA & UK established

Tool Room at Sharjah

2004

European Headquaters at Germany

Sheet Metal Die Design

2005

Injection Molding & metal Machining in Germany

JVs for

Environment Management Systems

Automotive Manufacturing Engineering

Plastic Molding & Metal Machining at Germany

PVC Tube Manufacturing


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2006

Wiring Harness Manufacturing in UK

Bus Airconditioning Systems

Auxiliary Equipment for Injection molding machines

Cabins for off road vehicles in India

2007

Rubber parts Manufacturing in Australia

JVs for

HVAC Systems, Meterclusters, Body Control Modules

& Compressors

Bimetal BandSaws

Transport & Stationary Refrigeration Systems

Thin Film coating metals

2008

JV for Lighting Systems, Pedal Box Assembly & Air Intake

manifolds JV for Precision machined metal components

2009

Visiocorp becomes a part of SamvardhanaMotherson Group

and renamed SamvardhanaMothersonReflectec (SMR)

Gear cutting tool manufacturing through a new venture

Motherson Advanced Tooling Solutions

Polymer Compounding

2010

JV for HVAC Systems for commercial vehicles & Off the

highway vehicles JV for Gear Cutting Tools

Freezers & Retail Refrigeration


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Product Design

MSSL provides design and development support to

customers with its large resource-pool of highly trainedand qualified design engineers Equipped with the latest

design software and prototype development facilities, ithas the capability to design from first principles.

Support Levels

Harness routing and layout study

Component Selection

Benchmarking

Source Identification

VA-VE at Design Stage

Onsite Engineering Support

Design Modifications

VA-VE after Launch

Component Development


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Component Identification and sourcing

New Component design as per specific customerrequirement

Tool development and prototyping

Component Manufacturing

Component Manufacturing

MSSL has a high degree of backward integration for manufacturing of criticalcomponents. The synergies with-in group companies enable in-house manufacturing of a

wide range of components, resulting in better quality control and shorter developmentlead times.

Wiring Harness Assembly

MSSL has manufacturing facilities near majorcustomer locations. MSSL has the capability to set updedicated production facilities for its customers.

Expertise in project management and a ready pool oftrained human resources enables MSSL to setup

green field projects in a very short lead time.


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Manufactruing Facilities

Multi-unit multi-locational manufacturing

Units and assembly lines designed as per specificcustomer requirements

Highly skilled manpower

Automatic cutting, stripping and crimpingmachines

Conveyorised assembly lines

100% electronic testing facilities

Online computerised Process control Process andjig designing with maximum Poka Yoke (mistake-proofing)

Facilities include specialised processes for varies

requirements such as Braiding, Heat Resistancewelding, Ultrasonic Welding, Online Printing etc.

Process Engineering

MSSL has in-house capabilities for design and

development of assembly processes. The processengineering activities encompass design and

manufacturing of Applicators, Jigs, Fixtures, AssemblyBoards, Circuit Checking Boards and Material

Handling Systems.

Logistics Support

Strategically located manufacturing facilities of MSSLprovide an effective logistics network. MSSL has unitslocated near major customer locations, following theconcept of Factory Next Door for high volume supplies.

For Overseas supplies, MSSL has locations near major portsin India supported by manufacturing bases in Sharjah, UAE,UK and a network of overseas logistics centers and

representative offices. MSSL is supplying to locations inAsia, Middle east, Europe and USA.


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Wire Harness


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The largest manufacturer of integrated wiring harnesses in India, theSamvardhanaMotherson group holds over 65% share of the Indianpassenger car wiring harness market.

The group manufactures wiring harnesses for the entire cross-section of theautomotive industry - from passenger cars to commercial vehicles, twowheelers and three wheelers, multi utility vehicles, farm, material handlingequipment and off-the-road vehicles. The group also manufacturesspecialised wiring harnesses for white goods, office automation, medicaldiagnostic equipment, electrical and electronic equipment.

Designing and developing wiring harnesses from first principle conceptson latest design software, the group provides total solutions in wiringharness manufacturing.

The group has complete backward integration for manufacturing criticalwiring harness components.

In-house capability for design and manufacturing of applicators, jigs,assembly boards and circuit checking boards enable process design controland flexibility.

The Engineering Capabilities for Wiring Harness

Process Design & Development

In-house capability of process design and validation

Designing & manufacturing of Jigs & Fixtures

Applicator design & manufacturing

Design & manufacturing of circuit checking & assembly boards

Tooling design for wiring harness process equipment, testing & assemblyequipment

Elelctrical Distribution System - Products


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Cable & Harness

Wiring HarnessLead Wire

Battery Cable

Flat Cable Harness

High Tension Cords (Engine Cables)

Wiring Harness Components

WiresTerminals

Connectors

Caps & Sleeves

Clamps & Binders

Fuse Boxes

A cable harness, also known as a wire harness, cable assembly, wiringassembly orwiring loom, is a string of cables and/or wires whichtransmit informational signals or operating currents (energy). The cablesare bound together by clamps, cable ties, cable lacing, sleeves, electricaltape, conduit, a weave of extruded string, or a combination thereof.

An array of insulated conductors bound together by lacing cord, metal

bands, or other binding, in an arrangement suitable for use only in specific

equipment for which the harness was designed; it may include

terminations.

In todays world of technology, the wiring systems for various

electrical equipments& machines have been improved &

systematized in form of WIRING HARNESSES. The connections tothe machines are controlled through machine control panel. The

panel switches & passive parts are joined by harnesses covered

with UV radiation resistant sleeves. We provide solutions for

mainly two types of equipments / machines.

The automotive connectors suitable to the specific applications

are crimped with wires of size required as per current rating.


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The components i.e. connectors, crimps, sleeves, etc., are

chosen according to the following specifications.

Commonly used in automobiles, as well as construction machinery,

modern-day cable harnesses provide several advantages over loose wiresand cables. For example, many aircraft, automobiles and spacecraft

contain many masses of wires which would stretch over several kilometers

if fully extended. By binding the many wires and cables into a cable

harness, the wires and cables can be better secured against the adverse

effects of vibrations, abrasions, and moisture. By constricting the wires

into a non-flexing bundle, usage of space is optimized, and the risk of a

short is decreased. Since the installer has only one harness to install (as

opposed to multiple wires), installation time is decreased and the process

can be easily standardized. Binding the wires into a flame-retardant sleeve

also lowers the risk of electrical fires.

Production

Cable harnesses are usually designed according to geometric and electricalrequirements. A diagram is then provided (either on paper or on amonitor) for the assembly preparation and assembly.

The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machineduring the cutting process or on a separate machine. After this, the ends of

the wires are stripped to expose the metal (orcore) of the wires, which arefitted with any required terminals and/or connector housings. The cablesare assembled and clamped together on a special workbench, or onto a pinboard (assembly board), according to the design specification, to form thecable harness. After fitting any protective sleeves, conduit, or extrudedyarn, the harness is either fitted directly in the vehicle or shipped.

In spite of increasing automation, in general, cable harnesses continue tobe manufactured by hand, and this will likely remain the case for theforeseeable future. In part, this is due to the many different processesinvolved, such as:

routing wires through sleeves,

taping with fabric tape, in particular on branch outs from wirestrands,

crimping terminals onto wires, particularly for so-called multiplecrimps (more than one wire into one terminal),

inserting one sleeve into another,

fastening strands with tape, clamps or cable ties.


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It is clearly difficult to automate these processes. In spite of this, theseprocesses can be learned relatively quickly, even without professionalqualifications. Thus, manual production remains more cost effective thanautomation. For certain vehicles, such as trucks, there are also a largenumber of variants (due to different configurations and the length of the

vehicles), which produce very small batch sizes (as low as one). However,the number of variants has been decreasing in recent years due to the useof data bus technology, such as a CAN bus, in conjunction with intelligentcontrol units. In spite of this, different variants are produced on the sameassembly board. Even here, man has an advantage over machine, since hecan change over to the different variants (no "re-programming" beingrequired).

Pre-production, however, can be automated in part. This affects:

Cutting individual wires (cutting machine),

crimping terminals onto one or both sides of the wire,

partial plugging of wires pre-fitted with terminals into connectorhousings (module),

soldering of wire ends (solder machine), and

twisting wires.

Testing the electrical functionality of a cable harness can be done with theaid of a test board. The circuit diagram data are pre-programmed into thetest board, where harnesses can be tested individually or in multiplenumbers.

Complex custom cable andwire harness development often involves thecollaboration of various departments and in some cases even organizationswhich presents a challenge in information sharing and design datapropagation through various departments. This challenge is based on thefact that separate departments operate in their spheres of knowledge andresponsibilities. It is possible to effectively evaluate and implement inputsfrom these separate entities through the enterprise-wide integration ofmodern software solutions, which allow collaborative technical designflow between large numbers of participants. The concept on which suchinformation systems operate is based on what is known as digitalcontinuity and, in the case of wiring components design, this conceptallows engineers, designers and other departments of the enterprise to

work closely and share pertinent information on all aspects of complexcabling products design and manufacturing. As a result, a wiring harnessmanufacturer achieves substantial gains in both cost reduction andproductivity.
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Since design of wiring components takes many stages and frequentchanges, the recordkeeping of the data related to the developmenthistory is very important to keep the wiring harness development ontrack. Wide network integration of shared CAD, PDM (ProductDevelopment Management) toolsets which support collaborative effortsmakes it possible to allow participants to quickly make updates, bridgingnot only internal departmental boundaries but also geographical division.

Modern wiring harness software applications allow creation of specificdesign rules which are based on OEM specifications for a particular

wiring harness or cable assembly piece. These rules are programmed intoECAD software and they allow wiring harness engineers to safely staywithin the predefined specs throughout the entire design process. Thesoftware intelligently applies the design restrictions to preventdevelopment errors.

Most ofwire harness manufacturingis aimed at large production quantitiesand the difference in manufacturing cost of a single piece can be easilymultiplied by hundreds of thousands of units. With the help of predefineddesign rules it is possible to find a cost saving alternative withoutsacrificing quality. Checking a new alternative against design rules takesvery little time in comparison with manual testing.

All of the development participants are provided instant access to criticaldata which allows expediting decision making and approval processes aswell as smooth transition from one development stage to the next.


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IMAGE 1 DESCRIPTION The flow of the wiring component designfrom its inception to manufacturing. The chart shows informationaccumulation and distribution throughout the entire enterprise.

Wire Harness Development Stages

Just like any product, the design of the wire harness or custom cable startswith its function definition. What this particular wire harness supposes todo and how? What kind of features will it have? Since we are discussingthe design of a complex wiring component, most likely there are a fewfunctions and features which have to be thoroughly defined. Therefore thefirst step in custom cable assembly design is an exact definition of itsfeatures and functions.


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The environment in which wiring component will be operating plays asignificant role in material selection. This includes external factors such astemperature, moisture, pressure, etc. These factors will define thematerials and components as well as types of connector assembly andterminals. In some instances, it may be required to develop a custom

crimping or soldering process. All this information flows from the OEMand used for the creation of predefined rules in the software.

All records of the design and development, as stated earlier, have to besecurely stored and accessible through the networks to all partiesinvolved. As the development process proceeds to the next stage, allinformation will be passed on to accommodate the next step. The amountof data accumulates as the development process goes further and allinformation is being intelligently managed by the software system.

In the next step, developers will engage in defining the physicalarchitecture of the wiring component which is driven by the earlierdefined features and functions. This will include components and wireselection, dimensions and type of terminal, splicing, etc.

Once physical architecture is determined, we enter into the next stepwhich starts the actual design process. In this stage we have to merge theelectrical engineering design data with physical design specifications.Here we can create mock ups in both actual and digital format, and furthercontemplate on the weight, appearance, connector and splicing types andcost. This also includes the consideration of the installation of the wiringcomponent in the manufactured product, may it be automobile, airplane ora dishwasher.

The aim of the design definition or the design intent is to produce a

technical drawing of the wire harness which defines all the details neededto produce at least a working prototype being as close as possible to atechnical drawing of the finished product ready for mass production.

The next step is the preparation of the design results for production.There is a distinction between the engineering of a wire harness piece andits design. Wire harness designers provide a product definition based onthe research and requirements but their data does not contain necessaryinformation to have a ready-for-production wiring component specs.Engineers are responsible for taking all the data passed on by the wiringharness designers and delivering a production-ready, compliantdocumentation.In this step wiring component engineers must define the exact cost ofproduction of the wire harness. Again, this is a critical task given the factthat mass production may involve thousands and possibly millions of unitsand any error may result in substantial additional costs. While designersmay use 3D design software tools, the engineers have to translate the threedimensional design into 2D (two dimensional) technical drawings. Thisincludes technical drawings of all elements, such as connectorcomponents, cavity components, clips, etc. Following are the areas of the


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wire harness engineers involvement:

Splicing Definitions:

Specifications of shielding, water proofing, solder sleeve position, cablestripping options, etc. These definitions derive from the manufacturingand QC guidelines and also may include custom manufacturingoperations.

Wire Harness/Custom Cable Component Selection:

This includes types of wire and cable used, plugs, terminals, connectortypes, tubes and others. It may also include the exact specification of theassembly of the individual elements because not all of the definitionsprovided by the OEM may contain exact specifications.

Wire and Cable Color Definition:

All of the wire components included in the wire harness must have anexact color definition. In some cases, where the wire inventory levels donot allow accommodating the tight production schedules, engineers mayfind substitutes and get OEM approval. This illustrates that engineers arealso responsible for component outsourcing and logistics when definingproduction-ready technical specs of the wiring component.

Production Estimates:

Engineers also are engaged in estimating the production timeline, tooling,assembly setup and other factors that contribute to wire harnessproduction lead time. This brings us to the next area of wire harnessengineers involvement.

Component Outsourcing Confirmation:

All the components involved in the wire harness assembly have to bepriced and delivered for cable assembly mass production. All sourcing andpricing information has to be entered into the system which also shouldaccommodate comparison of alternatives. All technical documentationmay be perfect but if a supply chain is not thoroughly inspected and thedelivery of the components is not assured, the production schedules are atrisk. In this stage, engineers work closely with procurement departmentsand pass gathered relevant data further into the next step.

Bill of Materials:

BOM calculation is performed at this stage and all data is saved in thesystem.

To comply with the OEM specification and delivery terms, theengineering team, production management team and procurementdepartment are working closely together to achieve a reliable productionschedule and secure all required components in time. Since wire harnessmanufacturing operates on small profit margins, all of the sourcing related


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factors must be taken in consideration and confirmed.

Often a custom cable manufacturerhas to deal with the multiple variantsof the wiring component which may include different lengths, terminaltypes, wire colors and electrical specifications. Understandably, thisplaces an array of additional requirements on the production schedulingand outsourcing. Because of the complexity and a large number oflogistical and engineering data, a modern computerized enterprise-widesolution is a great help for a modern wire harness manufacturer. Not onlydoes it help managing large loads of information but it also expedites thetasks associated with the manufacturing planning and productionscheduling, securing materials and accommodating OEM requests.

IMAGE 2 DESCRIPTION A master file of a wiring harness canaccommodate multiple variations for related products. Any changes indesign rules are automatically applied to all related product derivatives.

A true enterprise-wide wire harness design system accommodates productvariations which provide savings on tooling charges and productionscheduling because it can pass the information of the related wire harnessvariations to production management department, allowing faster andmore flexible production scheduling. A master design file and itsvariations provide a tree-like structure of the manufacturing procedurevariations and the software can separate the assembly process into batcheswhile optimizing production scheduling and providing an exact data on


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quantities and manufacturing instructions to all stages of the assemblyline. Defining wire harness variants as children of the master file allowmaking changes to the entire family of wiring components on the fly. Forexample, if in the design process, the length of a particular wiringcomponent has changed, this automatically updates all the variants which

contain that particular piece.

Design and Engineering Integrity of a Wiring

Component

In the initial stages of wiring component design, a set of rules is enteredinto the computer assisted design tools. These rules are defined by theOEM specs of the wiring component. A fully integrated system passesthese rules from one stage of the wire harness development to the next andthis allows staying within OEM specs at any development stage. Shall adesign rule be broken in the process, the software issues an automatedalert which allows wire harness engineers to correct an error immediately.

IMAGE 3 DESCRIPTION Wiring harness design data from multiplesources provided for engineers to create technical drawings for wireharness production. Passing wiring component design data to the wireharness assembly line for both equipment and human labor.

In some instances, the OEM engineering team decides to update thewiring component specs and requests that the wire harness manufacturer


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comply with the changes. If a wire harness contractor does not have afully integrated system in place, this can create a huge amount ofadditional work for many departments. A fully integrated wiring harnessdesign system, on the other hand, can adjust all subsequent steps simplyby changing some of the design rules and that will pass all the design

changes and update the project files automatically.

Design rules can apply to physical product architecture, safetyrequirements, wire and termination selection, data transfer protocols,electrical engineering standards, etc. You can view design rules as thelogic behind the design intent. Through the proper integration of thedesign rules, engineers can also control the cable assembly manufacturingprocess for wire cutting, stripping, type of crimping, molding, etc. Whilethere are many pre-set design rules in most cable design softwarepackages it is critical that they are fully customizable for each particularproject and the wire harness designers and engineers are highly skilled indefining the custom rules and understanding their actions and affects.

Custom Cable and Wire Harness Prototyping and

Manufacturing

At this point we have all the data and technical drawings necessary tobuild a working prototype worthy of manufacturing. Since all of theaspects of the wiring components procurement has been secured, we havethe BOM calculated and our manufacturing process is predefined and wehave a pretty good idea of the production cost, we can prototype thewiring component with confidence. All of the steps taken previously cometogether; we have a virtual cable assembly prototype in the system and allwe have to do is to produce a template of the form board and assemble the

physical wire harness.

To develop a complex wire harness form board is not an easy task but thesoftware can do it instantly and provide a template (an exact scale map)with critical data to ensure manufacturing accuracy. This data can includesuch things as visual aids and instructions for the product assembly.Again, since all the design and engineering information of variousdevelopment stages is passed on and checked through the applicationdesign rules, we have a complete manufacturing documentation related toevery step of production. Furthermore, advanced systems can pass thisinformation to the assembly line equipment directly eliminating manualequipment setup. This can be used for an automated setup of cutting,

testing and crimping equipments.

Fully integrated wire harness design solution allows faster turnaround inbuilding complex cabling prototypes and production setups. It alsoexpedites the manufacturing of wire harnesses through generatingoperational instructions for each part of the assembly line whether it ishuman labor or automated process.

Changes in the wiring component design are propagated through the entire


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chain of the wire harness development and easily checked againstpredefined rules this ensures design integrity. Modern systems alsoallow ease of recycling of previous wire harness design data of similarproducts and a full or partial integration of that data into a new project.

Comparing traditional methods of a custom cable assembly design with amodern approach involving wiring components software tools integrationshows advantages in both cost reduction associated with design andengineering of a wiring component and shortened development timelines.Design data sharing across the entire wire harness contractor enterpriseeliminates redundant tasks such as double data entry, manual data reviews,etc. and allows to expedite OEM orders.

Overview Mssl

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