Wire Harness Sourcing

A harness is a harness right? Wrong! Each wire harness requires dozens of tools and processes carried out by skilled labor and can vary from harness to harness. Therefore it is important to understand and appreciate how variation from the manufacturing norms can potentially impact the quality of your harness and the reputation of your product. Here are just a few things we think you should consider while sourcing your wire harness designs:

Quality:  Depending on your application, TS 16949, ISO 9001, or AS9100 are examples of quality standards that you should look for in a manufacturer as a minimum and build leaders are typically trained to IPC/WHMA-A-620 standards.  Beyond this there are many nuances that can be applied to evaluate a suppliers level of quality and whether it is suitable for your specific product type and application:

Capabilities:  You should assess the manufacturer's capabilities, including the tooling and human resources required for your project, as well as their ability to reach your volume requirements.  Consider the location and whether there is a large enough labor pool and if the company is operating efficiently and employing solutions that aim to speed up efficiencies while reducing errors.

Lead time: Take into account the lead times of the supplier to make sure they adhere to your production plan.  Consider whether minimum stocking agreements for completed assemblies or specific components should be negotiated to ensure the wire harness is never holding up your production line.  

Cost: Evaluating bids from multiple manufacturers can give you an idea on cost, but keep in mind that cost shouldn't be the only factor unless your wire harness design is relatively straightforward and for very general purpose.  In any case, when evaluating suppliers on cost, be sure you are giving them all the same inputs including your purchase quantities and EAU's.  Additionally, it is important to be sure that your designs are very well documented with detailed outline drawings and wiring diagrams.  It also helps reduce the time to quote by having excel data files that include the full BOM, wire from/to lists, and other detailed and digitalized information. This is where a digital software solution like EB Cable can really accelerate the product development process by digitally connecting OEM's with their long-term suppliers throughout the product development process.

Reputation: To evaluate a manufacturer's dependability and level of client satisfaction, look into their reputation and customer reviews.  It is a good idea to get advice from other professionals in the industry to determine if the wire harness manufacturer is someone you can depend on for your critical parts.

Experience: Take into account the manufacturer's expertise in creating wire harnesses for your particular sector or use case.  Does the management have experience in developing wire harnesses and do they understand the challenges and your application well?

Flexibility: Seek out a manufacturer who can adapt to changes in your specs or volume of production.  Be open where you are in your process, typically manufacturers or industry partners like BWS have experience with your situation and can help you to understand the timeline and important steps along the way.

Location: Take into account the manufacturer's closeness to your business when determining shipping costs and times.  Consider the full material supply chains involved for your product including the wire, connectors, and protective materials.  Longer supply chains can mean larger future costs and longer lead times.  Working with an industry partner like BWS can help you to minimize future costs and navigate the pros and cons of various supplier locations you might be considering.

We hope this was a helpful guide to get you started on finding the right manufacturer to support your projects but if you need further assistance, BWS is here to help!