Manufacturing

The humble cable harness is an unsung hero of electronics products, quietly doing its work to keep wires connected to power sources and linking components to ensure smooth, reliable, continuous operation. Cable harnesses organize and streamline wires within products and are critical to long-term performance. Cable harnesses may seem simple, but as products become more sophisticated and components continue to shrink in size, they are becoming more complex, able to work in challenging environments that require corresponding sophistication in design and assembly.

Benefits of Cable Harnesses

Cable harnesses are common in electronics products because of their many benefits. Well-designed and manufactured harnesses improve product production and performance in the following ways:

Choosing a strong cable harness manufacturer is critical to overall product quality and performance. Here's what to look for.

Decrease cost compared to manually installing wires one at a time.
Reduce installation time for projects involving extensive networks of wiring or cabling.
Improve the organization of cables, making identifying and maintaining connections easier.
Protect conductors from the elements outdoors or from chemical and moisture exposure indoors.
Reduce strain and stress on connections by supporting the weight of cables.
Improve safety by minimizing the risk of shorts or electrical fires.
Decrease installation and maintenance time by minimizing the number of connections and organizing components in a logical configuration.

Simple design principles amplify the benefits of wire harnesses. Sheaths protect wires against abrasion or exposure to hazards, minimizing the risk of failure. Connectors, clips, lacing, and other organizational elements reduce the space that wiring needs and ensure that technicians can easily locate components when needed.

Given the important role the cable harness plays in electronics devices, choosing a strong cable harness manufacturer is critical to product quality and performance. Here’s what to look for in a manufacturing partner.

Cable Harness Manufacturing Experience

No surprise here. The best cable harness manufacturers are usually the most experienced. While that may seem obvious, not all experiences are equal. For example, different industries have different safety and compliance requirements. Cable harnesses in the medical device industry must use approved components (wires, cables, interconnects, terminals, etc.) and meet high quality and performance standards. The automotive industry has its own material requirements for harnesses, due to high-temperature engine applications and the presence of corrosive gases and liquids, vibration, and exposure to outdoor elements like rain and snow. So make sure that your cable harness manufacturer has experience and a strong track record in your industry.

Cable Harness Manufacturing Certifications

Close behind experience comes certifications as an important consideration for selecting a cable harness manufacturer. Manufacturers must comply with the markets’ regulations and demonstrate a track record of creating products that pass industry testing labs. You should expect your manufacturer to have the necessary certifications for producing the type of cable harness you need. These include:

IPC: IPC is a trade association and standards body for electronic equipment and assemblies’ production requirements. IPC/WHMA-A-620 is the international standard for best practices and requirements for manufacturing cable harness.
ISO 9001: This is the international standard for a quality management system (QMS) in multiple industries, including cable harness.
UL/CUL: Underwriters Laboratories (UL/CUL in Canada) verify that products comply with safety standards for the United States and Canada, respectively. UL/CUL is the largest and oldest independent testing lab in the U.S. and its certifications are recognized by OSHA.
ETL: The Electrical Testing Lab (ETL) is another private lab recognized by OSHA that ensures products meet quality, health, environmental, safety, and social accountability standards.
ISO 13485: ISO 13485 is the international standard for quality requirements for medical device manufacturing.
TL9000-H 6.0/5.0: This is the quality management system for the telecommunications industry.
AS9100 REV D: The quality management system for aerospace manufacturing products.
ITAR: For aerospace and defense products, the International Traffic in Arms Regulations (ITAR) control the sale, manufacture, and distribution of defense and space-related services and materials on the United States Munitions List (USML).
RoHS: The Restriction of Hazardous Substances Directive (RoHS 1) guides the restriction of hazardous substances in electrical and electronic equipment in the European Union.

IPC/WHMA-A-620 is the most widely recognized standard for cable harness manufacturing and the most important certification for a manufacturer. Adhering to this standard ensures product quality, reliability, and consistency.

Cable Harness Components

While a cable harness may look like little more than a bundle of wires, it is, in fact, an intricate system of components—a subsystem within electronics products. Key components include:

Wires: Also called conductors, wires (usually copper) transit electrical signals and power. The choice of wire gauge, insulation material, and strand count can significantly impact the harness’s performance and flexibility.
Connectors: Fasteners that simplify the connection between wires and other components, acting like plugs to ensure secure connections.
Terminals: Metal components attached to the end of the wires that link to connectors to complete the connection.
Sleeving: Coatings protect wires from external elements, abrasions, and other potential damages.
Ties and Clamps: Straps that organize and support the wires within the device to reduce strain and facilitate maintenance when needed.
Ferrules: Tubes crimped over stranded wires to secure the strands within a screw terminal.

Cable Harness Wire Connections

Cable and harness assembly typically requires connecting different wires to enable electrical current to travel through the connection. The most common methods of connecting wires are soldering and crimping. Both processes help create secure connections for cables, and they produce long-lasting and high-performing cable connections.

Crimping

Crimping is the process of installing connectors on the ends of cables using a crimping tool, and involves stripping, cutting, and crimping terminals on either side of the wires. Whether manual or automated, proper wire crimping requires specialized tools and materials and must follow certain steps. High-quality crimps form gas-tight joints, which result from compressing specially designed splice bands or crimp terminals with cables and wires. Gas-tight connections prevent corrosion from moisture and oxygen.

Terminal crimping reshapes the strands in a wire to form a low-resistance electrical connection. The connections must be strong, with a single joint that has no breaks or segments, and the crimp must meet the height and width specifications established by the terminal manufacturer. It is important to avoid overly tight connections, as this can reduce the cross-section of the wire.

Soldering

Soldering is a traditional wire termination method and can be more cost-effective than crimping. With this method, alloys of tin, silver, or lead are heated and used to create durable joints that connect contacts to wire conductors. Soldering is commonly used in applications that require dependable power and signal connections.

While soldering offers certain benefits such as affordability, some disadvantages of soldering include:

Risk of heat-related damage in the connector, contacts, and cables
Risk of compromised connections due to vibration and corrosion
More time consuming than crimping

Cable Harness Manufacturing Design

Make sure the manufacturer you choose has an experienced engineering and production team capable of producing cable harnesses that meet design specifications and maintain high-quality standards. For example, one of your first decisions is whether to use automated or manual cable harness assembly. You can automate some steps in cable harness manufacturing, but manual production remains common. Automation is used more often when manufacturing at high volumes and using standard connections. However, complicated or non-standard connections can be produced more cost effectively by hand. Knowing your electronics manufacturer has the tools, know-how, and flexibility to design and produce the right cable harnesses for your device is critical to the success of your product.

Cable Harness Materials

The specific material used in a harness largely depends on its surrounding environment. If the wires are in an environment where moisture is present, for example, the harness should be of a material that is water resistant, such as polyethylene. Cables exposed to vibration or movement that might cause abrasion should be enclosed in a harness with a heat-shrink coating to minimize the effects of chafing. Some of the most common cable harness materials include:

Polyvinyl Chloride (PVC): PVC is a popular choice for low and medium-voltage wires and is common on indoor telecommunication cables due to its resistance to heat and moisture.
Fluorinated Ethylene-Propylene (FEP): FEP is tough and weather resistant, yet flexible. It’s also heat resistant, has dielectric properties, and is chemically inert.
Polyethylene: Polyethylene is lightweight, chemically inert, and ideal for high voltages. Polyethylene is available in different densities and has dielectric properties.
Nylon: Nylon is a popular choice because it resists weather elements, moisture, abrasion, and chemical reactions.
Thermoplastic rubber: A rubber material that stretches easily and returns to its previous state after stretching. It is also usable in high temperatures and resists damage from weather, chemicals, and aging.

There are many more options. Your manufacturer should be knowledgeable about cable harness materials and guide you to the right one for your application.

Cable Harness Supply Chain

Supply chain concerns impact every aspect of electronics manufacturing, including cable harness manufacturing. Make sure your cable harness manufacturer has access to the parts you need. Verify delivery times and costs. Check to see if they have multiple sources in multiple geographies to hedge against political, social, or climate disruptions. Supply chain management is another area where a design team can add value. Design engineers can propose alternative parts that are more widely available, cost less, or are less at risk of supply chain disruptions.

Cable Harness Testing

Bundling and connecting cables in harnesses creates multiple points of potential failure, making testing and inspecting finished products crucial to ensure consistent, reliable performance. Your cable harness manufacturer should have a robust testing and quality control process in place that includes:

Incoming material inspection: Make sure all materials received are in good condition. Defects to look for include:
- Damaged insulation
- Incorrect cable sizes
- Corrosion
- Moisture
Design testing: Ensure that the components in the harness assembly are suitable for the harness design.
Label verification: Check that the cables are properly labeled to avoid incorrect connections.
Hipot testing: Verify a cable’s ability to withstand high voltages.
Voltage Standing Wave Ratio (VSWR) testing: For RF and coaxial assemblies, check that radio frequencies don’t change when passing through the assembly.
Continuity testing: Test for circuit opens and shorts to ensure end-to-end signal integrity.
Resistance testing: Make sure resistance remains in acceptable ranges.

Critical Role of the Cable Harness

Cable harness assemblies are critical to electronics manufacturing. They are the vital conduits for electrical signal and power transmission and are integral to the functionality of every electronics product, from simple transistor radios to sophisticated spacecraft. The stability and reliability of wire connections keep products operating and safe. In short, electronic products are only as good as the performance of their components and the cables that connect those components.

Harness Excellence in Electronics Manufacturing

PRIDE Industries has years of experience in electronics manufacturing and cable and harness assembly across multiple industries. We have in-house engineers who can advise when certain crimp terminals would be better done manually due to the intricacy of the terminal or production volume. With a large library of manual and automated tools and customizable facilities, we can offer versatility and cost savings for prototyping and low-volume requirements. And because we set our standards high with IPC inspections and ISO certifications for quality control, you can rely on us to get your product right.

Learn More

Automotive Parts Manufacturer Finds Long-Term Manufacturing Partner

InterMotive Vehicle Controls is an automotive parts manufacturer that makes sophisticated vehicle control technology for public safety and transportation vehicles. When the company was looking to outsource production of components of its products, the company struck gold with an inclusive workforce provided by PRIDE Industries.

The Challenge: Consistent, Public Safety-Level Manufacturing

After working for years for Ford Motor Company, Greg Schafer, along with his spouse Linda, launched InterMotive Vehicle Controls in Auburn, California. As the company grew, they were searching for an automotive parts manufacturer partner to assemble some of the company’s PCBAs and cable assemblies. Finding a company that could provide the quality InterMotive needed for products that must withstand the rigors of public safety and public transportation use, and that could scale with the company’s growth, proved challenging.

The Solution: A Reliable, Skilled Automotive Parts Manufacturer

In 2003 InterMotive discovered PRIDE Industries, a contract electronics manufacturer with a mission to create employment for people with disabilities. “The company’s capabilities blew me away,” Greg Schafer said. “The people, the processes, and the technology are state of the art. But what sets PRIDE Industries apart are the people—I’d never seen a manufacturing floor where employees were so happy to be there.”

The Result: A Long-Term Partnership

Fast forward 20 years, and PRIDE Industries now manufactures 46 parts for InterMotive—24 cable assemblies and 18 mid to high-volume PCBAs. Services provided include functional testing of PCBAs, using custom text fixtures designed and built by PRIDE Industries engineers. Testing time has been reduced from about six minutes to 2.5 minutes, and returned boards have all but disappeared.

“We have directly hired people with disabilities and outsourced to PRIDE Industries for going on two decades now,” Linda Schafer said.

“I have employees with disabilities who started after high school and are now married and buying homes,” Greg Schafer said. “They love their jobs, show up on time every day, and are proud of their work. They really enhance our workforce.”

Vehicles for People with Disabilities

Coincidentally, one of InterMotive’s flagship products is a wheelchair interlock—a mechanism that immobilizes wheelchair-accessible vehicles when the wheelchair ramp deploys. “Some of our employees come to work in vehicles with our products on board,” Linda Schafer said, “products they may have helped build.” InterMotive is the largest manufacturer of wheelchair interlocks in North America.

Services Provided

PCBA and cable assembly
Functional testing
Custom test fixtures

Highlights

“The company's capabilities blew me away. The people, the processes, and the technology are state of the art. But what sets the PRIDE Industries apart are the people—I'd never seen a manufacturing floor where employees were so happy to be there.”

— Greg Schafer, Cofounder and President, InterMotive Vehicle Controls

cable assemblies

PCBAs

Testing time

reduced from 6 minutes to 2.5 minutes

99%

accuracy

Laser Manufacturer Improves PCB Contract Manufacturing Quality, Delivery Times

PRIDE Industries provides PCB contract manufacturing for Vortran Laser Technology, a company building ultra-reliable, high-performance laser solutions for the biomedical, medical, and industrial markets.

The company’s high-precision lasers perform cutting-edge scientific research such as flow cytometry, which analyzes cells by measuring their response to light; and optogenetics, where a laser activates light-sensitive proteins, called opsins, to control the activity of cells in living organisms.

The precision required to target invisible objects with an accurate beam requires equally precise printed circuit board (PCB) manufacturing. Parts need to be close to perfect.

The Challenge: PCB Contract Manufacturing Quality, Delivery Times

In 2020, Vortran had many issues with its PCB contract manufacturing partner. “Delivery times and quality were slipping, and costs kept increasing,” said Managing Director Chris Kruger. Unpredictable delivery schedules compromised Vortran’s ability to meet deadlines, and since the PCBs control laser performance, substandard quality is unacceptable.

“Our lasers need to be ultra-stable and reliable for 20 to 30 hours at a time,” Kruger said. “They have to deliver an absolute reference point for researchers.”

The Solution: Customizable Boards Save Time and Money

Kruger and Vortran turned to PRIDE Industries to improve on all fronts.

“We immediately improved delivery times and quality by 50 percent,” Kruger said. “And we were able to cut costs by 10 to 15 percent.”

Kruger worked with the PRIDE Industries electronics manufacturing team to develop a flexible PCB platform that allowed Vortran to use similar boards it could customize for specific products in the assembly process. The solution streamlined purchase orders and enabled higher volume purchases of platform parts to reduce costs and inventory. And reducing the number of boards to order helped mitigate supply chain strains during and after the pandemic.

Results: A Robust Supply Chain

“A significant benefit PRIDE Industries has delivered is having a robust supply chain,” Kruger said. “We have access to the parts we need, and the team is very good about communicating and anticipating any issues that might impact delivery times.”

But the biggest success factor is quality. “Before working with PRIDE Industries, we had to build a 15 percent excess to account for poor yield,” Kruger said. “That’s gone now. The technology—inspection and manufacturing tools—that they use and the quality they deliver are state-of-the-art.”

“We’re a relatively low-volume PCB manufacturer and appreciate that the PRIDE Industries team works with us to manage our runs and inventories so that it works for them as well,” Kruger said. “It’s a real partnership that is hard to find, especially compared to offshore manufacturers.”

Services

PCB Contract manufacturing

“We immediately improved delivery times and quality by 50 percent. And we were able to cut costs by 10 to 15 percent.”

— Chris Kruger, Managing Director

Highlights

10-15%

cost savings

50%

improvement in delivery times

50%

better quality

Brewery Solves Labor Shortage with Employees with Disabilities

Jerry Moore acquired Knee Deep Brewing Company in 2010, initially using a contract brewing facility in South Lake Tahoe to make beer and ship kegs to bars and restaurants just over the Nevada border in Reno. Fast-forward to 2013, when operations moved to its current home, a 37,000 square-foot, 40 BBL brewhouse with multiple 120 BBL fermenters. Unfortunately, labor shortages have been a persistent challenge.

The Challenge: A Reliable Workforce

“We had trouble finding reliable, hardworking employees to do the work.”

Like many front-line roles in the wake of the Great Resignation, the labor shortage faced by the brewering was real, and turnover was high and disruptive.

Moore came up with a novel solution. Just down the road from the Auburn, Calif., brewery was a job development center run by PRIDE Industries, training people with disabilities for real-world jobs. Moore reached out and a crew from the social enterprise started in 2020. It’s been a win-win relationship ever since.

“The first thing that surprised me was how happy they were to be here,” Moore said. “They show up on time, work hard, are a lot of fun, and have turned out to be a perfect fit.”

The Solution: Workers with Disabilities a Perfect Fit

Such a great fit that when Knee Deep launched its first special brew to call attention to Autism Awareness Month in April 2022, they named the beer Perfect Fit, complete with a PRIDE Industries logo on the cans to call attention to autism and promote the inclusion of people with disabilities in the workforce. The brewery made 10 barrels and sold out in a few weeks.

“It was an English-style IPA which people liked,” said Brewmaster Dean Roberts, “but I think people also liked the cause of autism awareness, and it gave them a reason to choose that beer.”

The PRIDE Industries team named the 2023 version of the April brew—Hoppy Roger—with a pirate-themed label that included caricatures of employees Aaron, Thomas, Zach, and Evan crewing the ship with a Knee Deep logo replacing the skull in the traditional Jolly Roger flag. This time the company made 30 barrels to satisfy demand.

Knee Deep donates a portion of proceeds to The Michael Ziegler PRIDE Industries Foundation, which provides programs to help people with disabilities, veterans, and foster youth—like the team working at the brewery–become job-ready.

“Awareness is great, but we want to do more,” Moore said. “We see the power of acceptance and inclusion and want to spread to the news.”

The Result: Contagious Enthusiasm

Should other breweries consider hiring people with autism or other disabilities? Yes, but not just brewers. “It’s not that different from hiring anyone else,” Moore said. “It’s finding the right person for the right job. This job happens to work for these individuals, and they love it.”

Take crew member Zach, for example. Ask him if he likes his job, and he answers immediately: “I love it.”

“They’re happy to be here, and that’s contagious,” said Roberts. “We’re all one team, and everyone enjoys working together. You don’t even think about the disability part anymore.”

It helps that a PRIDE Industries job coach is on hand to make sure everything runs smoothly.

“I love working with this team,” said coach Aaron Cartwright-Vasquez. “They’re great workers—I have to make sure they have what they need and take their breaks.” Cartwright-Vasquez provides transportation for those who need it and ensures everyone understands their schedules, which can vary weekly. “They’re waiting for me every morning wearing smiles.”

Untapped Labor Source

“Knee Deep Brewing has always been proud to have the best people working for it,” Moore likes to say. “Without them, we would not be where we are today. With great people comes great beer!”

More than 15 million people of working age in the U.S. identify as having a disability, an Accenture study found. The study found that companies that actively recruit and manage employees with disabilities have 28 percent higher revenue, twice the net income, and 30 percent higher profit margins. “Persons with disabilities have to be creative to adapt to the world around them,” the study said. “As such, they develop strengths such as problem-solving skills, agility, persistence, forethought, and a willingness to experiment—all of which are essential for innovation.”

Services

Packaging and fulfillment

“The first thing that surprised me was how happy they were to be here. They show up on time, work hard, are a lot of fun, and have turned out to be a perfect fit.”

— Knee Deep Brewing Company Owner Jerry Jones

In March 2023, ABC 10’s Mark S. Allen visited Knee Deep Brewing Company to report on the launch of its annual Autism Awareness Month beer. The specialty beer was inspired by several PRIDE Industries employees at the brewery who are on the autism spectrum.

See the video

The Perfect Fit is Knee Deep Brewing’s autism awareness beer supporting PRIDE Industries. The partnership began when Knee Deep hired employees with disabilties at its Auburn, California, brewery.

Read the article