This paper presents a compelling argument for optimizing the logistics flow of wiring harnesses within the automotive industry to address the rising production demands of vehicle manufacturers. It introduces an innovative assembly line structure specifically designed to boost efficiency and enhance responsiveness to client needs. Drawing from data gathered from an actual assembly line dedicated to producing engine harnesses for K9K engines, this study offers a practical and impactful foundation for its proposed optimization strategies. The new assembly structure effectively merges the benefits of a dynamic line—which emphasizes efficient space utilization and flexibility—with the strengths of a rotary line, particularly in light of the increasing complexity associated with harness production. The paper features a mathematical model that calculates cycle times for workstations within this new system architecture, optimizing the entire production process. Moreover, it illustrates how advanced modeling, simulation, and optimization techniques using WITNESS Horizon Version Release 25.0 can identify necessary adjustments for achieving optimal assembly line balance. Additionally, this research addresses pressing environmental concerns by proposing a robust recycling strategy for the scrap produced during wiring harness manufacturing. By advocating for sustainable practices and responsible waste management, the study highlights the importance of minimizing the ecological footprint of the automotive manufacturing process. In summary, this research provides essential insights and practical solutions for optimizing wiring harness logistics flow in the automotive industry. By implementing these strategies, manufacturers can significantly enhance their production capacity, improve operational efficiency, and maintain competitiveness in an ever-evolving market landscape.

Background: Integrating Radio Frequency Identification (RFID) technology into storage areas within the wiring harness manufacturing industry enables real-time component traceability and supports the implementation of fully automated inventory processes. While RFID systems provide continuous data regarding component type, quantity, and location, periodic inventory validation is still required to verify and correct records in the warehouse management system. Methods: This study examines the feasibility of passive ultra-high-frequency (UHF) RFID technology for automatic inventory management in a components warehouse. It also reviews relevant scientific literature on autonomous RFID signal measurement and Synthetic Aperture Radar (SAR)-based localization methods, which are subsequently adapted for inventory applications. An experimental setup is developed to characterize the reading field, hysteresis effects, and the influence of distance and tag orientation on detection performance. Results: The findings indicate that RFID-based automatic inventory is achievable with high accuracy and stability, especially when tag trajectories correspond to areas of high detection probability and antenna polarization is optimally configured. Conclusions: The proposed RFID-based system can be implemented with minimal hardware changes and low investment, thereby improving stock accuracy, traceability, and operational efficiency in automotive component logistics.