5 Key Questions to Ask When Hiring a Custom Wire Harness Manufacturer

Make Sure Your Potential Harness Partner Has the Answers You’re After

 

Wire harnesses are critical components when it comes to the performance of countless electronic devices, supplying the power and data to make them work reliably. When you need custom wire harnesses manufactured, you’ll want to look for a trusted partner that can deliver a high-quality yet cost-effective product, on time and on spec, while providing a seamless, satisfying experience. 

The one you choose will become an integral part of your supply chain, so finding one that checks all the boxes requires careful vetting on your part. You’ll have to ask the right questions and make sure you get the right answers. Here are five of the most important ones to answer when looking to hire a custom wire harness manufacturer:

 

1. Do They Support Custom Design & Prototyping?

Many applications require harnesses tailored to specific electrical, mechanical, or environmental requirements, which means your standard off-the-shelf solutions won’t cut it. In that case, you’ll want a company like CAI with an experienced technical team who can provide custom design and prototyping, such as in-house CAD (computer-aided design) capabilities that can simulate fit and function using digital models. 

A manufacturer that supports rapid prototyping and iterative testing can help you finalize a design more quickly and avoid downstream issues. Choosing a supplier that can offer guidance during the design phase should improve product quality while also saving you time and cost during production.

 

2. What Is Their Production Capacity & Lead Time?

Whether you’re developing a one-off prototype or scaling up to high-volume production, your partner should not only meet your current needs but also be flexible enough to grow with your business. Getting an idea of what their production capabilities are is critical, which is why you should ask about what volumes they can handle and their typical lead times. 

Long lead times driven by key or unique component specifications or other supply chain delays can severely impact your go-to-market timeline, so you’ll want a partner like CAI who can handle your project as quickly as possible, no matter the size, and scale output to meet rising demand, should your product require ramp-up.

CAI is great at identifying source options in addition to maintaining inventory and access to standard components that can help speed up turnaround and reduce supply risk. CAI is happy to understand how they can provide kanban or vendor-managed inventory (VMI) programs, which can be a huge advantage in managing costs and delivery times. 

 

3. Are They Experienced With My Industry or Application?

Every industry presents unique technical and environmental challenges which often require different types of vastly different specifications. That’s why you should look for a company who has experience working in your industry or with similar applications. 

A manufacturer like CAI that has decades of experience with a wide variety of industries will understand your environment and what materials to use, how to protect against things like EMI, and how to design for harsh conditions or size constraints. 

Ask whether they’ve handled projects of similar complexity, and if they can offer any insight or examples that demonstrate their track record. A reputable wire harness partner should be proud to share their success stories and long-standing client relationships, so don’t hesitate to have them provide customer references or examples of past work.

A manufacturer with relevant experience will be better equipped to anticipate potential pitfalls and suggest improvements, helping you get your product to market faster.

 

4. Are They Certified to Adhere to Industry Standards?

To ensure product safety, quality, and legality, the right manufacturer should maintain appropriate compliances that demonstrate structured quality management systems. 

They should be familiar with IPC/WHMA-A-620, the widely accepted standard for cable and wire harness assembly. 

 

5. What Quality Control Measures Do They Have in Place?

A thorough quality control process is one of the most important aspects of wire harness manufacturing, as it reflects a commitment to preventing, detecting, and resolving issues. Reputable partners like CAI offer a broad range of testing and automated test equipment to check everything from continuity and shorts to strength and durability. 

Find out the specific quality measures they use and whether they test every unit or just perform sample testing. A company that emphasizes robust quality procedures will help you minimize warranty claims and avoid costly field failures.

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These are five key questions you should ask in order to find the best custom wire harness partner for you and your project. At CAI, with over 35 years of satisfied customers, we pride ourselves in checking off all the boxes and ensuring you have the highest quality product, cost- effective solutions, and an optimal customer experience. Connect with us today to discuss how we can help bring your vision to life.