7 Tips for Outsourcing Your Wire Harness Manufacturing ...

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Outsourcing your manufacturing for wire harnesses or cable assemblies comes with many benefits. You will improve the efficiency and flexibility of the manufacturing process. However, the process can be daunting for many businesses looking to outsource their manufacturing successfully.

A lot of time and materials go into the wire harness manufacturing process, so you must get it right the first time. If you want to ensure that outsourcing your wire harness manufacturing process is successful for your business, do the following seven things:

1.Set a Realistic Timeframe for Delivery
2.Create a Prototype Wire Harness
3.Begin with an Initial Small Order
4.Work with an Excellent Customer Support Team
5.Confirm the Specifications are Correct
6.Use an Experienced Company
7.Emphasize Quality Control Testing

Focusing on these seven things will have a much better experience working with a manufacturer. Keep reading to learn more about seven tips for outsourcing your wire harness manufacturing.

What are the Benefits of Outsourcing the Manufacturing Process?

Outsourcing various aspects of the manufacturing process come with many benefits, especially for wire harnesses. Some of the most significant benefits are increased production capacity and efficiency. Companies invested in manufacturing wire harnesses have developed strategies for faster production.

If you receive a sudden spike in business demand, an experienced manufacturer will have the facilities to accommodate. One of the most significant advantages is lower labor costs for overseas manufacturers. You will not need to worry about hiring employees to keep up with the demand to create products.

1. Set a Realistic Timeframe for Delivery

If you want to reduce stress during the manufacturing process, you should give yourself plenty of time for delivery. When meeting tight deadlines, you have less room for error and need everything to go flawlessly. The average overseas freight delivery takes between 20 to 30 days. You should set a realistic timeline during your initial product order that includes potential delays.

Your first product order will be the most important you make with a manufacturer. This order will set the production steps for all of your future orders, so don&#;t rush the process. Make sure that you and the manufacturer are on the same page when discussing delivery times. Once you have learned how long production takes, you can plan accordingly for future shipments.

2. Create a Prototype Wire Harness

Most experienced manufacturers can custom-make a wire harness for initial testing. If you are creating a new wire harness, making a prototype first will allow you to fix any flaws in the product. You can work closely with the manufacturer from initial development to prototype creation.

As you test the prototype, you will also gather insights to tell the manufacturer when making the product. It&#;s crucial to make a prototype in product design and work with a manufacturer early in the development to choose readily available components. If the raw materials are hard to source, this could result in production delays.

3.Begin With an Initial Small Order

While developing a relationship with a manufacturer, it is best to do a small batch order of products. Small orders will verify the quality and ensure the specifications are met without bulk ordering. Investing in the production of thousands of wiring harnesses before making sure they are correct can be a costly mistake.

In wiring harness manufacturing, even the smallest detail can result in a product not fitting the specifications. Be clear about your requirements for the manufacturer and check to see if your small order meets your expectations. Once you have verified the quality, you can invest in a bulk order of products.

4.Work with an Excellent Customer Support Team

There is more to working with a wiring harness manufacturer than the product quality. The quality of customer support is something you shouldn&#;t undervalue when choosing a manufacturer for outsourcing. Cooperation is a crucial part of the manufacturing process that will require regular communication with customer support.

If you need immediate modifications on a wiring harness design or an unexpected shipping delay, customer support will be a crucial asset. A responsive and professional customer support team will be there if challenges happen during production. They will keep you updated throughout production and give updates.

5. Consult About Specifications

Bulk ordering wire harnesses is a complex process that involves purchasing raw materials and manufacturing several components. The wire harness design is the most critical part of the process. Before production, you must consult with the manufacturer regarding the design and explain any unclear specifications.

The design specifications should be detailed, and the project engineer should develop a high-quality prototype. Additionally, an experienced manufacturer will provide recommendations if you aren&#;t sure about a design spec. Don&#;t be afraid to ask questions, as it will help you get on the same page.

6. Use an Experienced Company

One of the best ways to ensure outsourcing your wire harness manufacturing goes well is by hiring an experienced company. A professional company will have completed numerous orders similar to yours, developing a proven manufacturing strategy. Some of the things you should ask your manufacturer to understand their experience is:

&#;How many years have you been in business?
&#;What products have you successfully manufactured in the past?
&#;Could you explain your quality control testing process?

Any experienced company will be glad to answer these questions and show examples from past customers. Working with an experienced company will make a massive difference in the production quality of your wire harnesses. You can count on the business to deliver your product on time and with the correct specifications.

7. Emphasize Quality Control Testing

If you want to receive a bulk order of high-quality products, emphasizing quality control testing is crucial for your success. You want each wire harness to go through strict testing to ensure it meets your requirements. When speaking to a manufacturer, you should always ask for their quality control standards.

Many manufacturers will be glad to show you their detailed testing process. Experienced manufacturers will put each wire harness through a series of tests and check the continuity within the system. With strict quality control standards, you can know that you are receiving a shipment of high-quality wire harnesses.

Conclusion

Outsourcing the manufacturing process of wire harnesses will allow you to receive top-quality products with more flexible demands. However, you will need to follow the tips in this article to achieve good results. Not doing proper research and working with an inexperienced business can result in costly mistakes.

Caption: A heat gun is used to heat shrink the tubing into appropriate size

In this step, a heat gun is used to heat shrink the tubing at an appropriate temperature to allow reduction of tube diameter up to its optimal size to protect the parts.

5.1.8 Attaching the Wire to a Male Housing

When attaching a wire into a male housing, pushed into the terminal inside it until a &#;clicks&#; in place. Once this is completed, the housing flap will be closed.

5.1.9 Connecting the Wire to the Female Housing and Attach the Connectors

The same procedure as above is performed in attaching the female housing. The wires are then tied into a bundle and thus concludes the procedure in wire harnessing.

Chapter 5.2 Wire Harness Testing Procedures

The testing procedures such as described below ensures that wires in a wire harness are fit for application use. to ensure their products are fit for application use. The tests need to be performed in reference with IPC or WHMA guidelines, summarizing the standards on assembly and production of electronic equipment and assemblies.

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5.2.1 Electrical Testing

The entire wire harness assembly is assessed for opens and incorrect wiring.

5.2.2 Visual Testing

As the name implies, the cables and wires are visually inspected for any defects and deformations. Sockets, markings, connectors and finishes are checked in this test and the dimensions are also inspected to ensure that the wires and cables pass the specifications.

5.2.3 Environmental Testing

In a virtual environment, these wires and cable harness are further tested to see if they are capable in withstanding harsh environmental elements such as vibration, extreme cold and heat and other factors such as the following:

Thermal shocks
High humidity levels
Salt sprays for corrosion

5.2.4 Mechanical Testing

This stage of testing focuses on the connectors, and the overall durability of the product. The connectors are subjected to disconnection and connection to determine how much force is required to connect or disconnect the assembly. Product durability is tested by subjecting it to a set number of flexing cycles. This helps the tester determine the approximate service life of the assembly.

It is important to come up with a testing plan, which comprises the necessary tests to ensure the performance of the product. Thorough cable assembly testing will ensure that cable will perform as required in extreme environments, and have a long service life.

CHAPTER 6. Quality Control and Quality Standards

Subtitle. We are proud to provide high-quality products and solutions to our customers

The starting point for compliance at Scondar is our strict compliance with manufacturing standards, enveloped with our excellent employee and customer governance maintaining the highest standards of ethical and legal conduct.

In this regard, our products are all qualified in the following standards such as in ISO , ROHS, OSHAS, IAF, and UL certified. With dedicated service and innovative products, we ensure complete customer satisfaction.

Chapter 6.1 ISO :

ISO : is the leading management standard for companies that trade on a business-to-business basis.

As ISO : certified, Scondar&#;s quality management principles are upheld with a strong customer focus, motivation and implication of top management in the process approach and

continual improvement.ISO : helps ensure that customers get consistent, good quality products and services, which in turn brings many business benefits.

There are seven quality management principles covered in this standard. These are:

QMP 1 &#; Customer focus
QMP 2 &#; Leadership
QMP 3 &#; Engagement of people
QMP 4 &#; Process approach
QMP 5 &#; Improvement
QMP 6 &#; Evidence-based decision making
QMP 7 &#; Relationship management

Chapter 6.2 Restriction of Hazardous Substances (ROHS) Compliance Accreditation

A wire or cable product labeled RoHS compliant follows the guidelines listed by the European Union under the Restriction of Hazardous Substances Directive (RoHS). This ensures that Scondar wire harness and connectors does not contain hazardous chemicals and elements such as lead, cadmium, mercury, hexacalent chromium, polybrominated biphenysis or polybrominated diphenyl ethers.

Chapter 6.3 China National Accreditation Service for Conformity Assessment

This certification is a third party attestation that indicates reliable technical competence of a facility.

Chapter 6.4 SGS Accredited

SGS is the world&#;s leading inspection, verification, testing and certification company that is known for recognizing companies with high quality manufacturing and integrity in leadership.

With Scondar&#;s SGS accreditation, we are confident to attest that:

• Our traded goods are delivered in justly with true quantity at superb quality, meeting all regulatory requirements across different regions and markets
• Our staff are all knowledgeable and experienced in electronic cabling, wire harnessing and producing high quality connectors, with safety features and reliable performance.
• We have a demonstrated organized and advanced processes, systems and services which are compliant with both national or international standards and regulations.

Chapter 7. Low to High Volume Wire Harness Assembly Projects

Scondar has the ability to produce custom wire harnesses from either a single conductor jumper up through multi-conductor with wire bundling. With the addition of heat shrink tubing and twisting options, we can customize wire harness assembly designs to any unique design. Along with many possible lengths and gauges, we also offer multiple termination options.

Chapter 8. Scondar can help you achieve your quality goals

By aligning our business processes with requirements set out in the following standards we are able to assure customers of our ability to deliver unrivalled levels of service and product quality.
Our quality system covers all activities that impact the service we offer to our customers and is fully embedded into our overall business management systems. It ensures that we uphold the following principles:

• We communicate with, and listen to, our customers.
• Being proactive in anticipating customers&#; needs and expectations.
• We safeguard our customers and ourselves by maintaining statutory and regulatory compliance.
• We provide marketing, technical and support information that is readily accessible and easy to understand.
• We continually strive to improve our operating processes, products and services for the benefit of our customers.

Chapter 9. Frequently Asked Questions (FAQs) about Wire Assemblies

How many Wires does an assembly have? How do you decide on the specific specifications to put?

• The number of wires may vary depending on your need. We will guide you on how to choose the proper connector to use for each application, the number of wires and other technical details through our field of engineers and experts.
• In general, a simple system may require a wire or cable assembly with five to seven wires. Larger assemblies may consist of more wires. The cables are selected based on the kind of data that they will be transmitting. The length, insulation material, wire size, and power capacity, are all decided based on the application.

What is the General Lead Time for Cable Assembly Delivery?

• The delivery depends on of factors, including material availability, production requirements, and inspection time. We can typically deliver your products within two to four weeks.
• Generally 5 -7 days for standard products not over 10,000 quantities.
• 7 &#; 14 days for big amount and customs product. Let us know if it is urgent.

Do you provide samples ? is it free or extra ?

• Free samples are always available for testing or quality evaluation purpose.

What is your Terms of payment ?

• Payment terms are flexible. T/T, Paypal, L/C, D/A, D/P, Western Union, MoneyGram payments etc.

What kind of Testing Procedures are Performed for Standard and Custom Assemblies?

• Testing is performed during and after the manufacturing process. As the wire assemblies are being produced, the products and components are continually checked for aspects such as weld peel, overmolding, pull and wire retention forces.

Other testing procedures performed during and post manufacturing include:

• Leak testing
• Hi-pot testing
• Impact testing
• Connector separation force testing
• Mate and unmate cycle testing

What types of Wire Assembly Designs are Generally Offered by Scondar?

Wire assembly designs may come off in different styles as the ones listed below. Our products are usually a replacement for branded connectors such as AMP, Hirose, Molex, JST and Yeonho in which the designs are similarly made.

Point-to-point Assemblies: This consists of terminal strips, which are used to create interconnections between two individual points.
Multi-Termination Type Assemblies: These are made up of multiple fiber cables that are pre-terminated. This means that connectors are added to each fiber cable before the assembly is created.
Ribbon Assemblies: Ribbon assemblies are insulated wires that are connected side-by-side forming a flat ribbon. Ribbon assemblies can be subcategorized into high-speed, shielded and jacketed non-PVC, split or multi-branch cable assemblies.
Radiation Tolerant Designs: These cable assemblies are designed to maintain their performance in applications with high amounts of radiation. Generally, radiation tolerant assemblies have a tolerance range from 5 to 200 Mrad.
Crush Resistant Designs: These assemblies can withstand immense amounts of pressure. You can find assemblies with the ability to withstand over 250 lbs. per inch.

These are some of the basic questions that first time customers need to know when procuring cable assemblies. Ensure that you have every query answered before you order a product. Clear knowledge of the products, its features and benefits, can help you make a wise decision.

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