Wire Harness, Cable & Electromechanical Assembly worked example

Assembly Complexity Score with assembly failure severity rating of 3 score: a worked example in wire harness, cable & electromechanical assembly

This worked example runs the assembly complexity score numbers for a tougher week than the baseline: assembly failure severity rating of 3 score instead of the typical 6 score. Estimate assembly complexity for wire harness, cable and electromechanical assembly using production-ready inputs so teams can rank risks and decide which issue needs containment, controls, or escalation first.

The inputs for this scenario

  • Assembly failure severity rating: 3 score (the input this scenario stresses; the baseline uses 6)
  • Complexity-driven occurrence rating: 4 score (held at the documented default)
  • In-process detection rating: 3 score (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Assembly complexity risk score = assembly complexity severity score × assembly complexity occurrence score × assembly complexity detection score.
  • Assembly complexity risk score works out to 3.35 score at these inputs, and this is the headline figure for the scenario.
  • Assembly complexity severity score works out to 3 score at these inputs.
  • Assembly complexity occurrence score works out to 4 score at these inputs.
  • Assembly complexity detection score works out to 3 score at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where assembly failure severity rating sits at 6 score and the headline result is 4.55 score, this scenario comes in 26.37% below the baseline at 3.35 score.
  • Use it during process FMEA, design-for-assembly reviews, or when triaging which complex harness variants to error-proof first. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Assembly complexity risk score: 3.35 score (headline result)
  • Assembly complexity severity score: 3 score
  • Assembly complexity occurrence score: 4 score
  • Assembly complexity detection score: 3 score

Run it with your numbers

  • To rerun this with your own numbers, open the live Assembly Complexity Score calculator, set assembly failure severity rating to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.