Step 1: Automated Cutting & Stripping
The journey begins with precision. Using high-speed automated machinery, wires are cut to exact lengths specified in the DFM analysis. Our tolerances are strictly controlled (typically +10mm / -0mm) to prevent installation tension.
Step 2: Sub-assembly & Waterproofing
Before main crimping, we perform "pre-assembly." This includes sliding on heat-shrink tubing, weather seals, and connectors. This phase is critical for automotive wire harnesses where IP67 sealing is required.
Step 3: High-Precision Terminal Crimping
As we discussed in our failure analysis guide, poor crimping is a leading cause of field issues. We utilize automated crimping presses with integrated Crimp Force Monitors (CFM).
"We perform pull-force tests and crimp height measurements for every batch to comply with IPC/WHMA-A-620 standards."
Step 4: Harness Board Assembly (The Nailboard)
Wires are routed onto a 1:1 scale assembly board (Nailboard). This ensures every branch length is accurate. Our technicians follow a "Insert, Click, Pull" protocol to guarantee connectors are fully seated.
Step 5 & 6: Final Integration & Visual QC
Protective coverings—such as convoluted tubing or braided sleeving—are applied based on the DFM specifications. Every finished harness undergoes a 100% visual inspection.
Step 7: 100% Electrical Continuity Testing
No harness leaves Cablum without a computerized continuity test. We check for open circuits, short circuits, and miswires to ensure 100% reliability.
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