From Prototype to Production: A Guide to Our Cable Assembly Manufacturing Process

Our Cable Assembly Customization Process

We are committed to providing custom wire and cable assemblies that are perfectly tailored to the unique requirements and restrictions of the customer and their application. As such, we generally proceed through each project following a carefully constructed customization process, which ensures we fully understand the customer’s expectations and specifications before we develop and deliver a solution. Below, we provide a step-by-step overview of this process.

Step 1: Meet With the Client

The first step in our cable assembly customization process is meeting with the customer. The point of this meeting is to ascertain the requirements and restrictions they have for their cable or wire assembly solution, which can include manufacturing location, tooling, and more. This information is key to developing a suitable proposal.

Step 2: Develop a Proposal

Once we’ve identified the part and production specifications and standards, we create a proposal to present to the client. It can include, among other elements, where prototype and production units will be manufactured, where and how any necessary tooling or production fixtures will be sourced or made, and who will supply the required raw materials.

Step 3: Receive Proposal Approval From the Client

If the customer approves the proposal, we proceed with ordering any raw materials needed for the project. We then generate two prototype units, one submitted for customer approval and one retained for reference in subsequent manufacturing operations if the former is approved. We also form a production plan to facilitate the transition from the prototyping to the production phase if the customer approves the prototype.

Step 4: Receive Prototype Approval From the Client

If the customer approves the prototype, we transfer the retained prototype unit and production plan to the manufacturing location to start production operations. We perform a final quality control (QC) check to verify the production units match the specs and standards of the prototype unit.

Step 5: Deliver Results!

If the production units pass the final QC check, we continue production until we make enough units to fulfill the order. Afterward, we deliver the finished cable or wire assemblies to the customer.

Good Manufacturing Practices for Cable Assemblies

Given the important role cable assemblies and wire harnesses play in many electrical and electronic systems, it is essential to pay careful attention when designing and manufacturing them to ensure they are built properly for the intended application. Some good manufacturing practices we implement during our custom cable assembly projects include:

• Verifying documentation. All product drawings and specifications are reviewed by our engineers to confirm manufacturability and compliance with all requirements and restrictions.
• Calibrating and validating tooling. All crimp tools are verified for the capability to yield good quality crimps.
• Performing crimp pull tests. All crimps are inspected and subjected to a tensile pull strength test to prove they meet strength requirements.
• Implementing automated wire processing. Wire cutting and stripping operations are performed using automated wire processing equipment with precise setup and control capabilities to prevent the nicking or cutting of strands and keep wire lengths within tolerance.
• Utilizing fully trained and highly skilled assembly technicians. All operations within the assembly process—from wire preparation to crimping to soldering to harness layup—are performed by expert assembly technicians who follow strict training protocols and performance controls.

Equipment Used for Custom Cable Assemblies

Our team utilizes state-of-the-art manufacturing technology to ensure we produce the best possible cable and wire assemblies for our customers’ industrial applications. The equipment we use includes:

• Semi-Auto Bench Crimpers
  • Union
  • JST
  • AMP K
  • AMP G
  • AMP ELT
  • MOLEX TM-40
• Wire Cutting Machines
  • Ideal
• Cutting & Stripping Machines
  • Komax Kappa 210
  • Schleuniger & Marker
• Cable Testers
  • Cirris (Easywire, 1000-M,1000-L)
  • Cablescan (90H8-512pts)

Qualities to Look for in a Cable Assembly Manufacturer

Whether you require a simple or complex cable assembly, the manufacturing partner you choose can significantly impact how easily or terribly your project proceeds. While there are many cable assembly manufacturers that may be able to meet your part and production needs, they are not all equal. Each company may have different experiences, expertise, and equipment that make them suitable for designing and manufacturing different types of cable and wire assemblies. Understanding these differences is key to identifying the right partner for your project.
Some of the key factors to consider when vetting your options include:

• • The most important consideration when choosing a cable assembly manufacturing partner is whether or not they can handle your project. Your partner should have experience completing a project similar to your own, whether that means a similar product or industry application. This experience demonstrates that they understand what you need from your cable assembly solution and how to fulfill it.
  • The cable design and assembly processes require engineers and technicians to have a high level of skill. Otherwise, they may not be able to create a good design or perform the necessary operations. Your partner should have employees who are highly experienced and fully trained, both of which are important to ensuring the manufacture of a high-quality solution.
  • In addition to having prior experience and skilled employees, the company you select should have the equipment (i.e., machines and tools) needed to handle your part and production specifications. Additionally, if you plan on forming a long-term partnership, they should demonstrate a willingness to invest in new technology as required for future projects or to remain competitive.
  • Cable assemblies with faulty components can cause problems in the electrical and electronic equipment in which they are installed. That’s why it is essential to partner with a manufacturing company who carefully vets suppliers to ensure they use only quality materials in your products.
  • Your manufacturing partner should be committed to providing you the best possible cable assembly for your application. They should have systems in place to guarantee they meet your specifications as well as any relevant industry or government standards.
  • Ultimately, you want to partner with a cable assembly manufacturer who can serve an appropriate solution for your problem. They should be open to any feedback you may have and willing to answer or address it if needed, whether that means adjusting a design or providing test samples. Additionally, they should be able to deliver the solution as agreed upon in the contract (e.g., product specs, production quantities, deadline, etc.).

Partner With Carr Manufacturing for Your Custom Cable Assembly Needs Today

Cable assemblies are a key component of various electrical and electronic devices and systems. That’s why it is vital to partner with a manufacturing company you can trust to deliver quality components.

At Carr Manufacturing, we design and manufacture high-quality, custom cable assemblies. Equipped with extensive experience, two ISO-certified manufacturing facilities, and dedicated employees, we have what it takes to assist with nearly any cable assembly need. From prototype to production, we will work with you to develop the perfect solution for your application. For general information about cable assemblies, check out our blog. To learn more about our capabilities, contact us today.