Why Do Wire Gauge Sizes Seem To Work Backwards?

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Something that has been a constant source of confusion within many circles, is the question of why do wire gauge sizes seem to be the opposite of what we think they should be? As a wire increases in physical width the gauge of that wire will decrease in numerical value. This seems backwards but, there must be an explanation to this that makes some form of sense.

Determining Wire Gauge Sizes 

Given an example of the wire gauge chart in Figure 1.1 we can see there is an extreme difference in physical size between a 0 gauge wire and that of a 30 gauge wire. The physical size of the 30 gauge is substantially smaller than that of the 0 gauge wire. Why is this?

The physical size of a wire is defined by the number of operations that it takes to get it to that physical size. This process means that a 30 gauge wire is much smaller in size than a 0 gauge wire. This process is called “Wire Drawing” and it looks like Figure 1.2. “Wire Drawing” is what gives us all of the different gauges that are seen in Figure 1.1.

A way to think about the wire drawing process is to think of the process of taffy pulling. Just like that sugary deliciousness, the wire starts off as one larger wire mass. Also, like taffy pulling wire drawing stretches and decreases the physical size of the wire making it longer and thinner. The process of wire drawing and decreasing the gauge of a wire also reduces the current that is traveling through the wire. By reducing the current in smaller gauged wires there is a decrease in the amperage that can be handled.


wire gauge

Figure 1.1 (Standard Wire Gauge Chart)


Figure 1.2 (Wire Drawing to Decrease Wire Gauge) (Kingway)

Now that you know how wire gauges are measured you are ready to start your own wire harness journey!

If you are interested in designing your own wire harnesses check out our new Wire Harness Estimator to get a quote!

If you need more information before you get started check out our blog on The Wire Harness Estimator Components Defined

You can also learn more about our pre-designed wire harnesses by checking out our Wire Harness Page!

Interviewing a Wire Harness Manufacturer – Part 4


Asking Challenging Questions Gains Valuable Information 

When considering outsourcing services to a custom manufacturer of any industry, asking challenging questions is critical for selecting the best fit possible. Having a list of tough questions prepared brings tremendous value to the process. Since we are a Wire Harness Manufacturer, we will specifically address Interviewing a Wire Harness Manufacturer.

At this stage, you have narrowed the field down to either a single or hopefully a few candidates. Now is time to begin the interview process. Asking tough interview questions will help lead you to the valued partner that you desire. This partnership will take your business to the next level. At least, that is the goal. 

For example, do you find the company accessible and responsive? To vastly increase our response time with customers, we recently launched the Falconer Electronics Wire Harness Estimator. This new tool allows customers the ability to gather an estimate immediately. Click here for more details. 

Outsourcing Your Wire Harness Assembly Process 

We are continuing our series on going through the entire due diligence process of selecting a custom manufacturer to outsource products. This week we suggest a list of questions to ask when Interviewing a Wire Harness Manufacturer.

So far in previous weeks, topics have included: 

Outsource Your Wire Harness Assembly Process – Part 1

Selecting a Wire Harness Manufacturer – Part 2

How to Find a New Wire Harness Manufacturer – Part 3 

Being overly prepared and asking the right questions can save you a great deal of grief and frustration down the road. Hastily jumping into a new relationship with a custom manufacturer that turns sour can be devastating and difficult to recover depending on the severity. 


50 Questions When Interviewing a Wire Harness Manufacturer

To help discover if you are compatible with a custom manufacturer that you are interviewing, below are a list of helpful questions to consider:

  1. What industries do you serve?
  2. Please describe your ideal customer? 
  3. Greatest victory in your business career or at your company? 
  4. Biggest let down or setback and how did you resolve? 
  5. Could you share exciting changes taking place at your business?
  6. What are you absolutely best at?
  7. What are your greatest weaknesses?
  8. How long have you been in business?
  9. Who are your key employees? 
  10. Describe the experience of staff?
  11. Do I have access with the floor supervisor?
  12. Who is my main point of contact?
  13. What are your business hours?
  14. Do I have a contact on weekends?
  15. Who do I contact for an emergency?
  16. Are you properly insured? (Check with your insurance company to confirm requirements) 
  17. Can you supply 3 customer references? 
  18. Are you willing to sign a non-disclosure form? 
  19. What is your lead time on orders? 
  20. Are you able to tackle rush orders? 
  21. Should the customer supply parts or do you prefer to supply parts? 
  22. Do you have aggressive discount programs with vendors? 
  23. Do you take advantage of early payment discounts with your vendors? 
  24. What are your payment terms? 
  25. Do accept credit card for payment? 
  26. Are discounts available for early payment? 
  27. What is your shipping policy? 
  28. Could we compare discounts with UPS/FedEx to see who has best rates? 
  29. Who is responsible for damaged goods during shipping? 
  30. Do you accept blanket orders? 
  31. Will you inventory our raw parts or finished goods when necessary? 
  32. Are you willing to purchase new tools or equipment to complete projects? 
  33. Can we work with you on projections? 
  34. What software do you use for inventory management and scheduling? 
  35. Do one or two customers represent more than 50% of your annual sales? 
  36. Have you ever been sued or in a lawsuit? 
  37. Have you ever gone bankrupt? 
  38. How do we handle damaged goods or parts not working? 
  39. Can you describe your testing process and quality control? 
  40. What is the company mission or vision statement? 
  41. Is your company tech savvy? 
  42. Do you have a succession plan or exit strategy in place? 
  43. What makes your company stand above the competition? 
  44. Facets of your business that demonstrate your commitment to your customer’s profitability?
  45. Any industry standards or certificates achieved?
  46. Do you have a safety protocol? 
  47. What is your capacity level? 
  48. Have you experienced layoffs recently? 
  49. Are you profitable? 
  50. Please explain the reason a recent customer stopped buying from you? 

Interviewing a Wire Harness Manufacturer

Asking excellent questions goes a long way with any relationship. This list is just a suggestive list of helpful questions to consider when Interviewing a Wire Harness Manufacturer.

Thank you for reading this post. For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+, and LinkedIn.


Selecting a Wire Harness Manufacturer – Part 2


Last week we discussed, when is the right time to consider Outsourcing Your Wire Harness Assembly Process. We have found several scenarios where a customer approaches us for the first time when they are Selecting a Wire Harness Manufacturer. Let’s role play. Below are a few examples where a new customer finds themselves seeking a new supplier…….

New Product Design and Prototypes 

Congratulations! You have just completed a brand new electrical product design. You and your team (or maybe you are a team of one) just exhausted weeks and even months designing your new product that is going to be a home run! Now what? You need a completed prototype. Also, an estimate to see if your new design can be produced at a competitive price. 

You can go to the Falconer Electronics Wire Harness Estimator for an estimate on your prototype. You will find the Wire Harness Estimator easy to use and works extremely fast. A quick estimate allows you to determine the potential cost and competitiveness of your new product. 

Jumping Into Electronics 

You are in the purchasing department of a company expanding into electrical products for the first time. Management has challenged you to seek out and find the company who best demonstrates the ability to tackle this project. 

For example, let’s say a mid-sized manufacturer is expanding into electrical wiring.  We recently began working with a company that specializes in handicap transportation. They produced a new proprietary product line requiring wire harnesses and printed circuit boards. It was a significant savings for the company to outsource the wire harness assembly and printed circuit boards rather than to attempt to conquer the project themselves.

Vendor Divorce 

Unfortunately, you and your current supplier are no longer compatible. Who changed? It is like a marriage deteriorating quickly where “living like this” is no longer an option. Either quality has deteriorated, deadlines are no longer met, or prices continue to increase. Whatever the case may be, it is time for a change.  Losing a customer is deeply disappointing and discouraging. Our team works eagerly to maintain rock solid marriages with our customers. We also love working with new customers on the rebound. 

In-House No Longer Working Out 

Your company no longer finds it efficient or profitable to produce wire harness assemblies in-house. The task falls on your lap to find a highly qualified Wire Harness Manufacturer. Selecting a company that you trust is essential! This recently happened with a large customer. They found it much more cost effective and profitable to outsource their wire harness assemblies. Our team went on full throttle to make this a smooth transition. 


Selecting a Wire Harness Manufacturer

Selecting a Wire Harness Manufacturer

Selecting a Wire Harness Manufacturer does not need to be a stressful process. Outsourcing Your Wire Harness Assembly to an experienced company with a seasoned staff lends a tremendous competitive advantage for your company. A company that completes projects with the highest quality, effective pricing, and on-time delivery adds tremendously to your bottom line. Teaming up with a company dedicated to your success is critical. 


This post continues our series on the process of Outsourcing and Selecting a Wire Harness Manufacturer. Please continue reading each week as we explore the entire buyer’s journey and due diligence process when determining which Wire Harness Manufacturer will best satisfy your needs. 

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest.

Outsource Your Wire Harness Assembly Process – Part 1


Is it Time to Outsource Your Wire Harness Assembly Process? 

“Should we begin outsourcing our Wire Harness Assembly Process?”

This a common question our new customers typically ask themselves before reaching out to us. 

Many times in life, if the question crosses your mind, then odds are it is time to act. 

For example, is it time to discard those old ratty sneakers that offend everyone around you? Most likely it is time to let go. 

Do you eat the leftover seafood from Monday night – on Saturday? Probably not a good idea. 

You question if you are too old or if it is still cool to wear your KC and the Sunshine Band t-shirt – Duran Duran – New Kids on the Block – or whatever generation you are from. Then it might be time to hang it up.  Actually, that is a bad example. It is never time to grow up. Anyway…..

Wire Harness Assembly Process

If you have been asking yourself if it is time to outsource your Wire Harness Assembly Process, odds are the time has arrived. At the very least, it certainly doesn’t hurt to investigate further. 

Start by identifying what event occurred or how this question arrived. Understanding when, how and why this became an internal burden is an important step. 

What hold ups, hang ups, pull downs, drag downs, hiccups, throw ups, headaches, heartaches, belly aches, or pain in the “you know what” has occurred. Think about the moment where you thought to yourself, “there must be a better way”.

Start With Performing an Internal SWOT 

Start with a SWOT on your internal Wire Harness Assembly process. What are the company strengths, weaknesses, opportunities, and threats? Especially if you keep this process in-house.

Do the same procedure and create a SWOT if you were to outsource your Wire Harness Assembly Process. 

The next question becomes, “Who can solve this problem so we can focus on our core business”?

 A key to building a successful business is partnering with experts in a given field. Successful companies exist by solving a problem. Solving a problem requires developing an area of expertise. A proficiency that stands above the competition.

Partnering with Seasoned Professionals 

You need to partner with a company that thrives and works relentlessly to gain a competitive advantage. Also, one that creates economies of scale for you. Most importantly, a solution so tremendous that it just doesn’t make sense to perform these tasks on your own anymore. 

Can you change the oil in your car in less than 30 minutes? Is your time worth more than the price to have a quick stop oil change shop (Ex: JiffyLube) perform the task? 

As a business owner or manager, you hire professionals to strengthen your business and protect your assets. This list includes hiring an accountant, attorney, or insurance broker who have invested the time and energy to educate themselves on business law, tax codes or proper insurance policies. You rely heavily on these individuals to help you make critical business decisions. Surrounding yourself with highly trained and qualified professionals has the potential to pay huge dividends. 

Outsourcing certain tasks within the manufacturing process offer similar benefits. Teaming up with an all-star team creates a winning formula allowing you to maximize profits while minimizing risks. 

This post kicks off an eight part series on Outsourcing Your Wire Harness Assembly Process. We will weigh in on the due diligence and selection process as well as many other strategies and helpful tips. 

For more info on electronics manufacturing, please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest.