The Wire Harness Manufacturing Process

Wire harnesses are assemblies of electrical cables or wires that transmit signals or electrical power. They are commonly used in the automotive, aerospace, and telecommunications industries.

More specifically, a wire harness is a system that connects all of the electrical components in a vehicle. It is an integral part of any automobile and ensures that all electrical components are properly connected and functioning. The wire harness manufacturing process is complex and delicate, requiring great precision and attention to detail.

In this guide, we will discuss in detail what wire harnesses are and how they are manufactured.

What is a wire harness?

As stated above, a wire harness is a system of cables and wires that deliver electrical power or signals to vehicles or other machinery. The harness can also be used to connect two or more components in an electronic device. Wire harnesses are typically bundled together with zip ties, loom, or tape to keep them organized and protected from damage.

Wire harnesses are an integral part of any electronic device or vehicle. They provide a neat, organized way to connect all necessary cables and wires. Doing so ensures that electrical power or signals can flow freely between components.

Though they may seem like a small detail, wire harnesses play a big role in keeping everything running smoothly. In fact, a malfunctioning wire harness can cause big problems — from short circuits to complete system failures. That’s why it’s essential to keep them in good condition and replace them when necessary.

If you’re looking for high-quality wire harnesses for your next project, be sure to check out our selection at Partec, Inc. We offer a wide variety of options to choose from, so you’re sure to find the perfect fit for your needs.

How are wire harnesses manufactured?

The wire harness manufacturing process begins with a team of engineers who design the harness to meet the customer’s specific needs. The next step is to produce a design prototype, which is then tested for quality and durability. Once the design is finalized, the production process can begin.

Here’s the step-by-step guide for the wire harness manufacturing process:

1. Wire harnesses are manufactured by first stripping the insulation off the wires that will be used in the harness.
2. The exposed wires are then arranged in the order they will be needed, and routes are planned for them accordingly.
3. Once the arrangement is finalized, the wires are then soldered or crimped to the appropriate connectors.
4. The wire harness is then tested to ensure that all connections are secure and there are no breaks in the wiring.
5. The harness is then covered with a protective sleeve to shield it from the elements and abrasion.
6. The final step is to label the wire harness so it can be easily identified when it needs to be installed.

Wire harnesses are manufactured using various methods and techniques, depending on the size and complexity of the harness. Here are some of the more common methods and techniques to manufacture wire harnesses:

Wire bundling

Wire bundling is a process of organizing and grouping wires together using straps, ties, or other materials. This helps keep wires organized and tidy, making them easier to work with and less likely to become tangled or damaged. Wire bundling can also help to protect wires from being damaged by abrasion or other forces. Wire bundling can significantly impact your wiring harness’s longevity and performance when done properly. This method is typically used for small- to medium-sized harnesses.

Wire braiding

For larger or more complex harnesses, a wire harness manufacturer may use a technique called wire braiding. This involves weaving together multiple wires to create a stronger, more durable harness. This method is often used for automotive and aerospace applications where wire harnesses are subjected to extreme conditions.

Wire weaving

Another manufacturing method used for larger or more complex harnesses is wire weaving. Wire weaving involves interlacing individual wires together to form a strong, flexible, and lightweight structure. This method is often used in aerospace and automotive applications where weight and space are critical factors.

Wire wrapping

Wire harness manufacturers may also use a technique called wire wrapping. This involves wrapping multiple wires around a central core. This method is typically used for larger harnesses or those that need to be more flexible.

No matter which manufacturing method is used, all wire harnesses must undergo a rigorous testing and inspection process to ensure they meet the highest quality and safety standards.

Wire harness manufacturing by Partec, Inc.

Wire harnesses are an essential part of many electronic devices and systems. They provide the electrical connections between various components and allow them to communicate with each other.

Partec, Inc. is a leading wire harness manufacturer, providing high-quality products and services to a variety of industries. We are committed to providing our customers with the best possible solutions for their needs, and our team of experts is always available to provide support and advice. Partec, Inc. has more than 30 years of experience designing and manufacturing high-quality wire harnesses for various applications. Our products are backed by a 100% satisfaction guarantee.

Contact us today to learn more about our wire harness manufacturing services.

A Brief Intro to Electro Mechanical Assembly

Electromechanical devices and systems play a vital role in a wide range of industries and applications. As suggested by the name, they are made of a combination of mechanical and electrical components, which work together to perform a set specific task or set of tasks. Product examples range from consumer electronics (e.g., clocks and electric typewriters) to industrial equipment (e.g., electrical actuators and protection relays). The process of making these devices and systems is known as electro-mechanical assembly. Below, we provide an overview of this process, highlighting what it is and what to look for in a manufacturing partner.

What Is Electro-Mechanical Assembly?

Electromechanical assembly—also referred to as electro-mechanical or electromechanical assembly—is the process of combining mechanical and electrical components to create a device or system that uses electrical current to perform mechanical tasks. The final products can be referred to as electro-mechanical assemblies. 

Electro-mechanical assemblies are built by electromechanical equipment assemblers, who follow detailed blueprints to assemble the various pieces of the products. Since the individual components are often small, intricate, and/or delicate, workers must have good focus, coordination, and eyesight in addition to solid assembly skills. 

What to Look for in an Electro-Mechanical Assembly Partner

Given the important role electro-mechanical assemblies play in many products, it is essential to ensure they are designed and built properly. That’s why it is vital to find an electro mechanical assembly partner you can trust if you choose to outsource the manufacture of these components. Things to look for include: 

• Comprehensive engineering and design support. Your partner should have the resources to help you with all of your design and engineering needs, whether you need help designing a new assembly or validating an existing assembly design. 

• Detailed documentation. The assembly company you choose to partner with should be able to create the documents needed for each stage of the manufacturing process, including Bill of Materials, product spec sheets, and testing docs.

• Prototyping capabilities. Your partner should have the tools to create and test prototypes of your assembly to evaluate its construction and performance before it proceeds to full production. 

Partec, Your Contract Electro-Mechanical Assembly Partner

Need a manufacturing partner for your electro-mechanical assembly project? The experts at Partec are here to help. Equipped with over 30 years of electro-mechanical assembly experience and a state-of-the-art assembly facility, we have the knowledge, skills, and tools to assist with nearly any contract assembly need. To learn more about our electro-mechanical assembly capabilities, contact us today. To discuss your project requirements with one of our team members, request a quote.

A Brief Intro to Sub Assembly Manufacturing

In the manufacturing sector, companies are always looking for ways to streamline production processes and cut production costs. One solution many manufacturers rely on to reduce the amount of time and, consequently, the amount of money needed to produce products is subassembly manufacturing. Below, we provide an overview of this process, highlighting what it is, how it differs from assembly, and what benefits it offers.

What Is Sub Assembly Manufacturing?

Subassembly manufacturing—also referred to as sub-assembly manufacturing and subassembly manufacturing—is a process that involves pre-combining or pre-building components into assemblies. These premade pieces can then be joined to other subassemblies and components in subsequent assembly operations to form complete parts and products.

Assembly vs. Sub Assembly

“Assembly” is a general term that refers to the processes original equipment manufacturers (OEM) use to create complete parts and products. These end units are often made up of a number of individual components or collections of components. The term “sub-assembly” is used in reference to the latter as the components are first assembled together and then integrated into a larger assembled unit. 

Benefits of Sub Assembly Manufacturing

There are many benefits to including sub-assembly operations in the manufacturing process of a part or product. For example: 

• It reduces training requirements. In sub-assembly operations, the process of manufacturing a complete product is broken up into smaller steps, which allows each worker to be responsible for learning a portion of the process rather than the entire process from start to finish. As a result, it takes less time to train them in their responsibilities.  

• It improves assembly accuracy. Allowing workers to focus on assembling a single portion of a product rather than the entire product enables them to become specialists in that particular task. Over time, they will be able to complete their designated task much faster without making mistakes.

Outsourcing sub-assembly manufacturing operations to a third party offer additional benefits, such as:

• Shortened production time. When subassemblies are already created, the time needed to produce the final product is much shorter. Additionally, outsourcing assembly operations means that resources within the company can be redirected to other production needs, which can lead to greater production outputs. 

• Lowered equipment costs. Outsourcing a portion of a product’s manufacturing operations to a third party can eliminate the need for the contracting company to purchase certain pieces of manufacturing equipment.

• Increased scalability. Contract manufacturers generally have the resources in place to manage different production volumes. Outsourcing subassembly manufacturing operations to them makes it easier for a contracting company to scale production of their products up or down to meet current customer demand without having to make drastic changes to their personnel or equipment.

Partec, Your Contract Sub Assembly Manufacturing Partner

Looking for a sub-assembly manufacturing partner for your next project? Turn to the experts at Partec! Our extensive manufacturing experience, state-of-the-art assembly equipment, and comprehensive assembly capabilities make us the ideal choice for all contract assembly needs. To learn more about our contract assembly capabilities, contact us today. To discuss your project requirements with one of our representatives, request a quote.

An Introduction to Contract Manufacturing for Mechanical and Electrical Assemblies

Contract manufacturing is a type of business agreement in which one company (the contracting company) outsources some or all of its manufacturing operations to another company (the contract manufacturer). The contract manufacturer makes the parts or products to the specifications provided by the contracting company, which then uses them to create complete product assemblies or distributes them under its own brand.

This type of manufacturing relationship is highly beneficial to the contracting company. They can focus on other aspects of their business (e.g., marketing, sales, and distribution) without worry about investing time, money, and resources into building and running a production facility. Additionally, the contract manufacturer can give them access to industry experts or sourcing networks that help improve the quality of the components and/or reduce production costs.

Contract manufacturing can be used to make a variety of parts and products. For example, the experts at Partec provide contract manufacturing services for mechanical and electrical assemblies. Below, we highlight the types of contract assembly services available at Partec, Inc. and the industries that rely on them.

Contract Assembly Services at Partec

Partec, Inc. has provided industry-leading contract manufacturing services for mechanical and electrical assemblies for over 30 years. Our assembly capabilities include:

• Cable and wire harness assembly. Our team can assemble a cable or wire harness for nearly any application. We can handle cables and wires ranging from 24 AWG to 4/0 AWG and turn them into single-wire or multi-wire assemblies in production quantities of ten pieces to over 1,000,000 pieces.
• Electromechanical assembly. We offer electromechanical assembly services for a variety of components and devices, including, but not limited to, actuators, batteries, fans, fasteners, fittings, fuses, AC/DC motors, power supplies, relays, switches, and transformers. Whether you need cable and wire harness assemblies, control panel assemblies, or full box build/kit assemblies, we can meet your electromechanical needs. We also provide a range of engineering support services, such as manufacturing engineering, electrical engineering, controls engineering, and program management.
• Hand assembly. Our hand assembly services are ideal for assembly operations that require superior dexterity, agility, and decision-making capabilities. They enable us to handle small and delicate pieces, match customized items, and assemble highly complex and varied kits that would be otherwise impossible using automated assembly equipment. Our ISO 9001 certified quality management program helps ensure all of our hand-assembled parts and products meet high quality standards, regardless of customer size or production volume.

Industries Where Contract Manufacturing Makes Sense

Companies in a wide range of industries turn to contract manufacturing to produce their parts and products. Some of the industries that regularly utilize the contract assembly services at Partec include:

• Amusement and gaming
• Consumer goods
• Electronics
• Hardware
• Industrial machinery
• Telecommunications
• Transformers

Contact the Experts at Partec for Your Contract Assembly Needs

For quality mechanical and electrical assemblies, turn to the experts at Partec! Our extensive manufacturing experience, combined with our state-of-the-art assembly facility and vast range of assembly capabilities, enables us to produce the assemblies you need while saving you time and money. To learn more about our contract assembly capabilities, contact us today. To partner with us on your next project, request a quote.

All About Box Build Assemblies

All About Box Build Assemblies

The term “box build” (also sometimes referred to as systems integration) encompasses all of the assembly work—other than producing the printed circuit board (PCB) component—involved in manufacturing an electromechanical assembly. While the process is tailored to the specific part and project terms, it can include the installation of sub-assemblies and other components, running of wires and cables, and fabrication of the enclosure (i.e., box).  

At Partec, Incorporated, our team specializes in contract assembly solutions for small and large companies. We offer a full range of electromechanical box build assembly services to ensure each product we deliver fully meets client specifications. Below we outline the benefits of using box build assembly solutions for the manufacture of electronic and mechanical components and what to expect during a box build assembly project.

Benefits of Box Build Assemblies

Compared to other assembly methods, box build assembly offers many advantages when used for the production of electromechanical devices. Companies that partner with an experienced and knowledgeable box build service provider can achieve lower production costs without sacrificing control over the system design. By outsourcing assembly operations to a third-party, the contracting company can reduce the amount of time and money spent on purchasing and processing material and equipment. Additionally, they have an additional set of eyes on the project to ensure it proceeds as planned.

Considerations for the Box Build Assembly Process

As indicated above, the box build assembly process differs depending on the product being assembled. However, there are some commonalities across projects. For example, some of the key points of information to provide to a box build assembly service provider include:

•   Bill of materials (BOM). The BOM contains a list of all the components required for the production of the final product. It should also indicate what will be provided by you (the contracting company) and what will need to be purchased by the service provider.
•   3D CAD models. Design files facilitate the visualization of the final product. Additionally, some CAD programs allow designs to be converted into build and assembly instructions.
•   Sample units. A sample unit helps visualize the final product further. It can help fill in service providers on any product details if the product drawing or design is unfinished.
•   Dimensions. It is important to indicate the final product’s size and weight as it affects shipping, handling, and storage requirements.
•   Testing requirements. Once the assembly is finished, it undergoes testing to verify it meets various parameters. As a client, it is essential to tell the service provider what tests are necessary as they can range from visual inspections to full functional testing.

Contact the Experts at Partec, Inc. for Your Next Box Build Assembly Project

Save yourself time and money on your next assembly project by partnering with the experts at Partec, Inc. Equipped with over 30 years of electromechanical assembly experience and a state-of-the-art assembly facility, our team has the knowledge, skills, and tools to deliver high-quality box build and kit assembly solutions that meet client’s exact needs. To learn more about our assembly capabilities or partner with us on your next project, contact us, or request a quote today.