How much time does it really take you to install semi-trailer lighting?

TRALERT® closely follows developments in bodybuilding.
We share insights on where the challenges lie and translate that knowledge into smart, practical solutions that make workshop work easier and more enjoyable.

In this article, you will read our findings in the world of semi-trailer construction: 

• Why connecting lighting and cabling often takes more time than you think;

• Which operations take up the most hours;

• Why understanding assembly time is the first step towards a more efficient workshop.

Under every semi-trailer lies a story of technology and craftsmanship

Lighting in bodybuilding is no longer limited to rear lights and indicators. Every modern semi-trailer or heavy transport vehicle contains a complete electrical network of light points and auxiliary systems.

Think about:

• Contour and marker lights: dozens of lights distributed along the length and width of the vehicle, including marker lights with indicator function.

• Functional lighting: work lights, cargo space lighting, warning lights and flashing beacons.

• Signal lighting and safety systems: indicators, brake lights, EBS and ABS signals, sometimes integrated with CAN-bus or smart modules.

Each light has its own 24V cable, connector and attachment to the whole. So that makes for quite a web of cabling. With extendable semi-trailers or vehicles with modular surface mounting, those routes become even more complex.

Cabling should be protected from brine, oil, vibration and wear to prevent damage.

Hidden hours when connecting lighting

In practice, we see that lighting is usually still connected manually. That means: pulling cables, bundling, protecting, pressing flat plugs. All this comes together at the junction box. One focal point is the lighting bar at the rear. There is a relatively large amount of lighting here. Connecting all those lights to the cable junction boxes can be a time-consuming job.

So there is relatively a lot of manual work and thus assembly time in connecting 24V semi-trailer lighting. Whether semi-trailers, tippers, flatbed semi-trailers or special transport vehicles.

With increasing (ECE) regulations, this is not going to diminish any time soon.

Testing, final checks and looking for possible interference

After installing the lighting, it is time to test it all: measure voltage, check that everything works, detect any errors. Any error in connection (one cable wrong, bad connection, bad crimp) can cause hours of delay in detection.

Efficiency does not start with speed, but with understanding the time-consuming parts. 

Common problems with lighting in semi-trailer construction

Despite having professionals at work, a mistake is in a small corner and sometimes the lighting does not function correctly. This can be due to:

• Wrongly connected cables or loose connections

• Wrong or poorly connected surface connectors

• Damage to cables due to sharp edges under the chassis

• Time lost through repeated testing and fault-finding

• Younger fitters often have less experience with this manual work, which increases the risk of errors

• Poor-quality lighting with module faults

• Canbus-related problems

Flexibility and customer requirements

Customers may also come up with special wishes or requirements. For example, a row of symmetrical rear lights or additional warning lights and beacons.

• Customers have requirements for certain lights or cable configuration

• There is no fixed routing standard

• Every vehicle sometimes requires a different solution

What does this mean for your workshop?

Every minute lost in the mounting phase is lost margin. That is why it is very important to take a close look at the process to see whether it can be done more efficiently.

Companies that analyse their processes often discover that lighting and cabling are precisely the areas where you can gain a lot: less improvisation, more preparation, more standardisation.

Every minute lost in the assembly phase is lost margin. 

An efficient lighting installation process starts with insight into installation time

Working more efficiently starts with awareness. Understanding the time that lighting and cabling really cost quickly reveals where the hidden hours are.

There is also a lot to standardise. You can discuss this at any time with an experienced company such as TRALERT® to see where the gains for your company lie.