The Manufacturing Process of Wire Harnesses

Manufacturing wire harnesses might initially sound easy, however, manufacturing anything requires careful planning and testing before being shipped off to customers and clients. In this article, we will be walking through the process of everything you need to know in regards to manufacturing wire harnesses in an easily digestible format.

Wire harness manufacturers have to contend with more than you may think, but at the end of the day, the end goal is a quality product for any manufacturer who is serious at what they do. If you would like to know more on this topic, we would appreciate your time and to keep on reading,

Step 1: Design

Even though wire harnesses might seem simple, designing a wire harness does take consideration and is a major part of the overall manufacturing process.

It’s true that much of them aren’t visible, such as being tucked away behind a glove box, but some wires might need to be a specific/different color so the user can tell them apart when trying to diagnose something. In addition, if a client specifically asks for a certain type of design, you will need to take this into account when working on all the other aspects of the process.

Furthermore, designing electrical wires means that you have to take the internet conductors and wire size into account to ensure that enough of an electrical current can pass through.

Step 2: Prototyping

Prototyping is a concept that is physically manifested. They are designed to allow you to see what improvements you want to make and what path you wish to take with the product.

Most things that you own have had a prototype at some point: your car, phone, laptop, stove, microwave. They all needed a testing product. Cable harness manufacturers create and test prototypes in order to determine how the project is going.

Step 3: Production and Assembly

Once the product has been designed, manifested as a prototype, and is ready for prime time. It is now ready for production and assembly. This is a crucial process in not only getting the product to customers, but this is the do or die situation when it comes to quality. There is an expected standard that needs to be made throughout the entire process with minimal room for error. Here is what happens during this stage:

  • Wire cutting
  • Stripping & connections
  • Assembling the product

While autonomous machines are becoming more of the norm for a lot of industries, wire harness manufacturers still need humans since it is an intricate process that requires precision, in addition, it’s simpler to hire people than it is to have expensive machines that need trained operators and someone who knows how to fix it when things go wrong.

Part 4:Testing

Not to be confused with the prototyping stage, testing involves simply checking if the product is of high quality before shipping out the assembled wires. If all the above steps have been properly done, the company shouldn’t have much issue with moving on to the shipping portion of the process.

If you are needing custom cables for your business, searching “Wire Harness Manufacturing Near Me” should yield results, but we’d love to work with you.