Wiring harnesses are essential to numerous industries, making the choice of manufacturer crucial. There is a great deal of variation in the ways the cables can be bound, making room for wire harness companies to specialize in a specific type of harness.
To source the right manufacturer for your custom wire harness assembly, you should compare your desired specifications with their specialties, taking into account the factors below.
Why outsourcing works
As you begin your search for a wire harness manufacturer, you may be tempted to bring production in-house. However, while you would need to buy and maintain all the expensive machinery needed, manufacturers already have it.
Additionally, due to economies of scale, they are able to get a better price on materials than you could. Pinner Wire & Cable, Inc. boasts robust relationships with leading component suppliers, allowing them to negotiate a better price on your behalf.
Between the equipment cost and bulk material purchasing, outsourcing wire harness assembly saves you money - even with the charges from the manufacturer.
Manufacturer's equipment
One of the most critical factors when sourcing a manufacturer for custom wire harness assemblies is the equipment they use. If they use older or faulty equipment, your wire harness assemblies may fray or wear out more quickly.
Winar Connection Inc. uses a fully automatic Schleuniger Crimp Center 64 it purchased in 2013; the machine allows for higher performance and a lower setup time. They also use multiple fully-automatic crimping machines, a braiding machine and an ultra-sonic welder.
Certified quality and reliability
Good wire harness assembly companies care about their reputation; they will pursue appropriate certifications and comply with appropriate regulations in order to ensure they can provide the best product and service possible.
Arimon, for instance, is ISO 9001:2015 certified, RoHS compliant, has a UL- and CSA-certified assembly facility and conforms to IPC/WHMA A-620 Requirements and Acceptance for Cable and Wire Harness Assemblies.
Lead times and volume options
Depending on the quantity and lead time you need, a particular manufacturer may be unable or unwilling to deliver your wire harness assemblies. Make sure your chosen manufacturer fully understands your requirements, and is capable of meeting them.
Tack Electronics, Inc. originally made a name for itself by offering volumes and lead times that were not offered by conventional contract manufacturers. Today, it has retained and perfected its ability to offer orders of any size with short lead times.
Manufacturer size
Smaller manufacturers can only carry and deal with a small number of wires and cables, limiting your bundling options.
Cooner Wire, a larger manufacturer, boasts the largest inventory of flexible wire and custom cables; they work with wire sizes from 42 AWG mini coax to 4/0 AWG Extra Flexible Power Cable, ensuring that they will have a wire size that works for you.
But bigger is not always better. If you require a high-touch solution, a small company like J&S Products, Inc. might more capably meet your needs.
Quantity questions
There are several additional factors to consider related to quantities. The ideal company, for example, will offer blanket orders where you make a large order for delivery over several months. In this case, you would only pay the invoice for the shipped portion. You should also check if they have extra inventory on hand as a buffer quantity.
Additional options
Each wire harness assembly manufacturer has its own specialties. Repro Parts, Inc. performs value-added services on-site that allow you to optimize control over processes, quality and delivery. They also include in-process inspection, assembly electronic testing, automated wire marking (when required) and final inspection including all necessary documentation with every order.
Experience
The final factor you should consider is experience. Time in the field is a good indicator of the proficiency of a company. ConnectZone and RPC Manufacturing have been around for 13 years, NCA has been "doing it right" for over 30 years and Specialized Products, Ltd. has been around since 1967.
You may also consider the sectors that the company has experience in. NCA, for instance, has served in the aerospace, marine, construction, agriculture, lighting, theater and stage, cases, laboratory and fire equipment industries - and likely yours, as well.
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