IPC/WHMA-A-620: The Ultimate Guide to Quality in Cable and Wire Harness Manufacturing

From aerospace systems to medical devices, the performance of wire harnesses and cable assemblies can mean the difference between life-saving functionality and catastrophic failure. Yet, as demand surges for these critical components, manufacturers face a growing challenge: ensuring skilled labour and standardized processes to meet quality benchmarks. Enter IPC/WHMA-A-620, the globally recognized standard developed by the IPC (Association Connecting Electronics Industries) and WHMA (Wire Harness Manufacturers Association). This guide unpacks the standard’s structure, revisions, training programs, and role in solving industry challenges.

1. What is IPC/WHMA-A-620?

IPC/WHMA-A-620 defines acceptance criteria for cable, wire, and harness assemblies, encompassing processes such as crimping, soldering, splicing, and mechanical fastening. It categorizes products into three classes based on application criticality:

• Class 1 (General Electronics): Prioritizes functionality over longevity, such as in household appliances.
• Class 2 (Dedicated Service): Balances durability and performance for industrial and commercial equipment.
• Class 3 (High-Performance): Demands zero failures in mission-critical systems (e.g., aerospace, medical devices).

The standard emphasizes design for manufacturability (DFM) and environmental adaptability while avoiding overly rigid rules to foster innovation.

2. Key Updates in the 2023 Revision (Version E)

The latest IPC/WHMA-A-620E revision addresses modern manufacturing challenges with critical updates:

• Harmonized Soldering Standards: Aligned with IPC J-STD-001 for consistency in electrical assemblies.
• Clarified Terminology: Revised definitions in Appendix A eliminate ambiguity in acceptance criteria.
• New Content: Coverage of cutoff tabs and over-moulding for flexible flat ribbon cables fills previous gaps.
• Streamlined Structure: A renumbered chapter system improves usability for engineers and inspectors.

Earlier Revisions: The 2020 Version D removed outdated “target” conditions and integrated MIL-STD-1130 for solderless connections.

3. Testing for Compliance: Real-World Applications

To validate assembly integrity, IPC/WHMA-A-620 mandates rigorous testing. For example, copper wire solder joint tensile testing ensures mechanical resilience:

• Standards: Follow IPC/WHMA-A-620 and ASTM B913 protocols.
• Procedure:
  1. Prepare samples to specifications.
  2. Test using tools like the KZ-SSBC-500 tensile tester at a speed of 5 mm/min.
  3. Analyze peak force and variance across trials.

Such tests are vital for Class 2/3 compliance in high-stress industries such as automotive and telecommunications.

4. Training and Certification: Closing the Skills Gap

With skilled labour shortages plaguing the industry, IPC/WHMA-A-620 certification programs offer a structured path to expertise.

Certification Levels

• Certified IPC Specialist (CIS): Foundational training for engineers, quality staff, and operators.
• Certified Standards Expert (CSE): Advanced interpretation of standards for process optimization.
• Certified IPC Trainer (CIT): Authorized to deliver training and exams.
• Master IPC Trainer (MIT): Highest tier for CITs at licensed centres.

Who Should Get Certified?

• Quality assurance teams
• Process and design engineers
• Training managers
• Professionals in automotive, aerospace, or medical manufacturing

Key Training Modules

• Crimping, soldering, and insulation displacement
• Connectorization, shielding, and ultrasonic welding
• Labeling, installation, and compliance testing

5. Why IPC/WHMA-A-620 is a Game-Changer

David Bergman, IPC’s VP of Standards, emphasizes that the standard “harmonizes global expectations while driving innovation.” Its benefits include:

• Reduced Disputes: Clear criteria minimize supplier-buyer conflicts.
• Faster Time-to-Market: Streamlined processes accelerate production.
• Enhanced Trust: Certification signals commitment to quality, attracting OEM partnerships.
• Competitive Edge: Stand out in crowded markets with recognized compliance.

6. The ROI of Certification

Investing in IPC/WHMA-A-620 training delivers measurable returns:

• Improved Communication: A universal language aligns OEMs and manufacturers.
• Higher Compliance: Standardized workflows reduce errors and rework.
• Customer Retention: Certified manufacturers secure long-term contracts, ensuring stability and reliability.
• Industry Leadership: Build a reputation for reliability in critical sectors.

Conclusion: Elevate Your Manufacturing Standards

IPC/WHMA-A-620 isn’t just a checklist—it’s a strategic framework for excellence in an industry where precision saves lives and fuels innovation. With the 2023 E revision now live, manufacturers must prioritize training to bridge the skills gap and meet escalating demand.

Act Now:

1. Download the latest IPC/WHMA-A-620E guidelines.
2. Enroll your team in IPC training programs.
3. Partner with Industry Leaders: Collaborate with manufacturers like Romtronic, a trustedprovider of high-performance cable and wire harness solutionr. With decades of expertise in aerospace, medical, and industrial applications, Romtronic ensures your assemblies meet IPC/WHMA-A-620 quality benchmarks while accelerating time to market.
4. Contact authorized distributors for compliance support.

By adopting this standard and aligning with proven partners, you’re not just meeting criteria—you’re future-proofing your operations and positioning your brand as a leader in quality-driven manufacturing.

Why Partner with Romtronic?

• IPC/WHMA-A-620-Compliant Production
• End-to-End Custom Harness Design & Testing
• Proven Expertise in High-Reliability Industries
• Global Supply Chain Support

Ready to streamline your cable assembly process?

For training schedules, certification details, or licensing terms, visit IPC’s official website or contact accredited providers.

Alex Wang

Alex Wang is the Marketing Manager at Romtronic, holding a degree in International Business. With 7 years of sales experience in the electronic cable and harness industry, he oversees marketing efforts across North and South America. He deeply understands the industry and excels in market analysis, providing tailored advice to help clients better plan their purchasing and sales strategies.