关键词: 试制过程；线束端子；端子退针；四步法

Abstract: This article introduces the wiring terminal pin retraction issue that occurs during the new product trial production at a passenger vehicle manufacturing company, and describes how the problem is effectively resolved through the integrated application of quality tools and professional techniques. By applying the four-step method for problem solving (problem definition, problem analysis, problem resolution, and verification & solidification), a thorough and systematic analysis is conducted on product structure, material composition, component dimensions, supplier processes, logistics transportation, and factory assembly. As a result, five root causes are identified, including insufficient wiring harness length and low glass fiber content in the wiring terminal material. Corresponding corrective measures are implemented, such as optimizing wiring harness length and increasing the glass fiber content of the terminals. After verification on 30 000 units, no recurrence of the pin retraction issue is observed, and the problem is effectively resolved. A systematic review and knowledge sharing are also carried out to draw broader lessons, laying a solid foundation for subsequent new product development.

Key words: trial production process; wiring terminal; pin retraction; four-step approach