Famous Ground Strap

Today, let’s discuss “Almost Famous” Ground Strap Quotes that didn’t quite make it. 

You may not have realized how prevalent of a role that Ground Straps have played in movies over the years. 

However, when it came time for filming, many lines changed prior to final cut. 

Unfortunately, in most cases Ground Straps were cut out of numerous classic movies. 

For example, are you familiar with this line: “Ground Straps? We ain’t got no Ground Straps! We don’t need no Ground Straps!”

~The Treasure of the Sierra Madre, 1948

For some unknown reason they changed the lines to say “badges” instead of Ground Straps

Obviously this is deeply disappointing and we are not exactly sure why these lines were changed. 

Well, as they say in the movies, the rest is history (at least it seems like they say that). 

In reality, we have an extensive list of our favorite movies……..that originally were meant to include Famous Ground Strap Quotes which unfortunately changed. 

A little Trivia for you…..can you name the movie from the quotes below….(which were all SUPPOSED to say “Ground Straps“)? 

Famous Ground Strap Quotes (that never were) 

  2. “Life is like a box of Ground Straps.”
  3. “May the Ground Strap be with you.” 
  4. “Go ahead, make my Ground Strap.”
  5. “Frankly my dear, I don’t give a Ground Strap.” 
  6. “I’m going to make him a Ground Strap that he can’t refuse.”
  7. “I love the smell of Ground Straps in the morning.”
  8. “Strap. Ground Strap.” 
  9. “You’re going to need a bigger Ground Strap.”
  10. “Houston, we have a Ground Strap.”
  11. “Yo, Ground Strap.”
  12. “Hasta la vista Ground Strap.”
  13. “Ground Straps my dear Watson.” 
  14. “Nobody puts Ground Straps in the corner.” 
  15. “I’m king of the Ground Straps.”
  16. “You’re killing me, Ground Straps.”
  17. “Here is looking at you Ground Strap.”
  18. “I see Ground Straps.”
  19. “Ground Straps, for lack of a better word, is good.” 
  20. “Keep your friends close, but your Ground Straps closer.” 



  1. Jerry Maguire
  2. Forest Gump 
  3. Star Wars 
  4. Sudden Impact 
  5. Gone with the Wind 
  6. The Godfather 
  7. Apocalypse Now 
  8. James Bond 
  9. Jaws 
  10. Apollo 13 
  11. Rocky 
  12. Terminator 2
  13. Sherlock Holmes  
  14. Dirty Dancing
  15. Titanic  
  16. The Sandlot 
  17. Casablanca
  18. Sixth Sense 
  19. Wall Street 
  20. The Godfather II 

Wrapping It Up 

For more information on Ground Straps, please click these helpful links: 

Finally, to learn about Wire Harness Assemblies, please click below: 









Ground Straps

Ground Straps literally serve as life savers. Especially since not using Ground Straps can be a Shocking Experience.

Staying grounded means keeping level headed with your feet on the ground (as well as above ground). 

However, not being ground can lead to….bad times. 

Ground Straps

For example, a company recently contacted us in need of Ground Straps. 


While developing a new product during the prototype stage, the engineering firm that they had contracted with overlooked adding ground straps to their product. 

While they were demonstrating their new product at a trade show, the machine consistently issued out shocks to users. 

It was a mystery why their brand new product was dishing out electrical shocks. 

Failing to ground the product was the culprit. 

At a trade show of all places, while demonstrating their new product. Not an ideal situation. 

Ground Straps to the rescue. 

Avoid a Shocking Experience 

Shocking Experience

Ground Straps keep our customers safe. Ground Straps also keeps their customers safe. 
Not using Ground Straps can be a shocking experience. 
Being exposed to a live energy source can lead to severe injuries or even worse. 
The bottom line:
We have a saying for all DIYers: “When in Doubt – Ground IT” .
A few tips for avoiding shocks at home:
  1. Never overload a Power Strip 
  2. Stay clear of loose wires or broken outlets 
  3. Turn off the electrical supply of any device that you are working on or trying to repair 
  4. Call an electrician or take your repairs to a technician
  5. Stay clear of water when handling an electrical device 

Especially when you are in the shower or tub jamming to your favorite song, make sure your device is parked away at a safe distance.

Shocking Experience

Wrapping It Up 

Also, click below of helpful information about Wire Harness Assemblies:

Finally, for more information on Ground Straps, please click these helpful links: 

Falconer Electronics Quotebuilder

The Ground Strap Instant QuoteBuilder 

Create Your Own Custom Ground Strap 

Introducing the Instant Ground Strap QuoteBuilder at Falconer Electronics: 

  • Build Your Own Custom Ground Strap
  • Powerful and Resourceful Software Tool 
  • Takes Only 60 Seconds or Less 
  • Buy Manufacturer Direct & Save 
  • No RFQ Wait Time * No Frustration * No Obligation 
  • Made in USA 


When in Doubt – Ground It!


Do you need to be grounded? 

Not grounded like back in your teenage years. 

The type of grounded that keeps your products and customers safe. 

We are talking about Ground Straps, of course.

Staying grounded certainly makes sense (and cents). 

Ground Straps play a critical role with safety on electrical devices and electronics. 

Let’s say you are working on a new product design in electronics and you need this product grounded. 

Durable and reliable ground straps will solve this issue. 

You now need to find a potential vendor or supplier. 

Unfortunately you now need to submit your Request for Quote (RFQ). 

Then….the waiting starts.

Yet, you need a price. NOW! Not tomorrow. Not next week. Right this minute. 

Finally, no more waiting for your RFQ.

Falconer Electronics spares you the painful process of waiting for your RFQ when it comes to buying custom Ground Straps. 

The Falconer Electronics Instant Wire Harness Quotebuilder solves this very issue. 

Staying Grounded + Save Time + Compare Prices + No waiting for RFQ = Falconer Electronics Instant Ground Strap QuoteBuilder 


No RFQ Wait Time * QuoteBuilder Takes Only 60 Seconds or Less

Ground Strap QuoteBuilder


Who says an “old-school” manufacturer can’t create their own cutting edge software program? Well, Falconer Electronics did just that. 

Serving as a Ground Strap and Wire Harness Manufacturer since 1985, Falconer Electronics continues to produce thousands upon thousands of ground straps. 

Well to make life much easier for our customers, we decided to create our very own proprietary software, The Falconer Electronics Instant Ground Strap QuoteBuilder. 

You can customize your own ground strap. Literally within seconds. 

Then receive your quote sent directly to your email inbox. 

In addition, you can go ahead an place an order for your newly created custom Ground Strap as well. Immediately. 

Instant Ground Strap QuoteBuilder Benefits Include: 

  • Less Stress 
  • Fast & Easy
  • Compare prices 
  • Made in USA
  • Shipped Super Fast
  • Low shipping rates
  • Convenient. Efficient. Accurate. 
  • The industry leader in customizing ground straps. 
  • Lead or Lead free. 
  • Pick your connector size 
  • Select your orientation
  • Build Your Own Custom Ground Strap
  • Any length  
  • Large quantities 

Wrapping It Up 

Thank you for stopping by to check out this post. 

For more information on Ground Straps, please click these helpful links: 

Lastly, check out these links below which includes helpful information about Wire Harness Assemblies:


This past year has been extremely exciting for our company. Falconer Electronics recently joined the eCommerce party going on at Amazon.  

Why did we join the party? 

Due to popular demand from our eCommerce store, we decided to take the plunge and place our Ground Straps on Amazon. 


However, to take a step back, let’s take a look at the path we took leading up to adding our Ground Straps on Amazon. 

In particular, demonstrating how a custom manufacturer converts a proprietary process into a proprietary product. 

Proprietary Process into a Proprietary Product 

Ground Strap Names

As a custom Ground Strap and Wire Harness Manufacturer since 1985, launching a proprietary product line stepped outside our typical course of business. 

We found out first hand, when an “old school” manufacturer tackles change by embracing new technology, dynamic results follow. 

In this case, converting our proprietary process of manufacturing ground straps into a proprietary product line, created a new focus for our company. 

Especially since offering our Ground Straps on the Falconer Electronics website opened new doors that we had no idea existed. 

First, we took a product that we manufacturer thousands upon thousands for OEM’s (original equipment manufacturers). 

It just made perfect sense to turn this proprietary process into a proprietary product. 

Everything was in place. 

For example, we had the tools, equipment and resources.

Additionally, our team possesses the experience, skills and knowledge. 

Furthermore, solid relationships with vendors certainly helps with pricing and product availability. 

Most importantly, all systems exist to continue scaling production on our Braided Ground Straps. 

As a result, Amazon seemed like the next logical step. 

Ground Straps on Amazon

Ground Straps on Amazon


What is the first thing that comes to mind when you hear the word Amazon? 

Twenty years ago, you might have said a mighty river. A rain forest. Possibly, a natural wonder of the world. 

Today, your first thoughts when you hear the word Amazon most likely include convenience, an endless selection, free shipping and of course, a smiling box at your door step. 

With that in mind, the gargantuan success of might also make it a natural wonder of the world. Just by the sheer size of the company and the enormously high level of success. 

Consider this: According to Statista, Amazon surpasses 2 billion clicks per month. Yes, BILLION! 

That is insane!

Amazon serves as an incredible American entrepreneurial success story from its humble beginnings when it launched as one of the first eCommerce bookstores to the behemoth it is today. 

With $.51 of every eCommerce dollar going to Amazon, it made perfect sense (and cents) for us to create a presence on Amazon. 

We launched our Amazon store with 24 different types of Braided Ground Straps. 

The variety includes a mixture of 1/4″ and 1/2″ connectors: 

4″, 8″, 12″, 20″ 

  • Tinned Copper
  • 10 Gauge AWG
  • 53 Amps
  • Flat Width 1/2″

4″, 8″, 12″ 20″ 

  • Tinned Copper
  • 14 Gauge AWG
  • 32 Amps
  • Flat Width 1/4″

Benefits of Ground Straps from Falconer Electronics include: 

  • Made in USA 
  • Tinned copper 
  • Solder dipped ends 
  • Heavy Duty 
  • Manufacturing Ground Straps Since 1985 



Wrapping It Up 

Thank you for stopping by to check out this post. 

Below includes helpful information about Wire Harness Assemblies:

Also, for more information on Ground Straps, please click these helpful links: 


Wire Harness Manufacturing

Wire Harness Manufacturing is our foundation. It’s in our blood. Dating all the way back to 1985. The Team at Falconer Electronics Inc. (FEI) takes tremendous pride in manufacturing amazing products for our customers. In addition, as a Custom Wire Harness Manufacturer, assembling and delivering superior products is our mission. Actually, we are wire harness geeks so we call it our Crusade.

Wire Harness Manufacturing: Steps for Success

  1. Superior Quality
  2. Maintaining Impeccable Customer Scorecards
  3. Fast Turnaround Times
  4. Competitive Prices
  5. Highly Skilled and Seasoned Staff
  6. FREE Instant Estimates (click here)
  7. High Productivity
  8. Agility and Flexibility
  9. Company Culture Dedicated to Customer Satisfaction
  10. Lastly, a Commitment to Safety

The Secret to Success

Our wire harness assemblies can be found all over the country. Especially in the following places:

  • As you walk around Walmart or Lowe’s, you will walk past our wire harnesses. They can be found in the commercial power strips and electrical retail fixture displays.
  • If you drove past a semi-truck today (or if one went flying past you). Our wires may have been waving to you.
  • Our wires are in some dentist offices (not during a root canal – we refuse to contribute to that type of pain).
  • If you rode on a train today. Our wires may also have been riding along with you.
  • Another example includes our proprietary line of magnetic work lights and trouble lights
  • ATM Machines
  • Heating Systems
  • Handicap Accessible Transport Vehicles
  • Electrical Signage at retail cash registers as well as self check-out kiosks 
  • Along with Much More…

Try Our Custom Wire Harness Estimator

Receive an Estimate Sent Directly to Your Email Within Seconds

Helpful Guide of Wire Harness Manufacturing Terms, Tools and Tips 

Are you new to the Wire Harness process? Our team created a helpful guide below.

The Wire Harness Manufacturing Guide includes:

  • Wire Harness Terms
  • Tools
  • Tips of the Trade

Additionally, the list below includes a number of Wire Harness Manufacturing Terms and definitions.

Wire Harness Manufacturing IPC/WHMA-A-620 Standard 

All of the Wire Harness Manufacturing Terms below are from the IPC/WHMA-A-620. This serves as an industry standard. Therefore, providing criteria for commonly used wire harness assemblies.  Consequently, the standard sets a “collection of visual Quality Acceptability Requirements for Cable, Wire and Harness Assemblies.”

To learn more about the IPC/WHMA-A-620, click here.

Wire Harness Manufacturing Terms and Definitions

American Wire Gage (AWG)

A standard system for designating wire diameter. Primarily used in the U.S.


The raised portion at the front and/or back of the wire barrel crimp that provides a gradual entrance and exit for the wire strands without causing damage.


Wire Strands that have separated from the normal lay of the wire.


Woven bare metallic or tinned copper wire used as shielding for wires and cables and as ground wire for batteries or heavy industrial equipment. Also, a woven fibrous protective outer covering over a conductor or cable.


A group of individually insulated conductors in the twisted or parallel configuration under a common sheath.

Cable Assembly

A cable with plugs or connectors attached.


An uninsulated wire or the conductor of an insulated wire suitable for carrying electrical current.


A tube in which insulated wires and cables are passed.


A device used to physically and electrically join two or more conductors.


The conducting part of a connector that acts with another such part to complete or break a circuit.


A continuous path for the flow of current in an electrical circuit.


Final configuration of a terminal barrel formed by the compression of terminal barrel and wire.

Crimp Height

The measurement of the overall wire barrel height after crimping the terminal.


Total current is the combination of resistive and capacitive currents. Resistive current is present in both AC and DC DWV tests. Additionally, the capacitive current is present only with fluctuations in applied voltage (Ex: AC testing).


Any insulating medium that intervenes between two conductors.

Double Crimp

The process of two or more mechanical crimping operations on the same location in a single terminal.


A short tube. Used to make solderless connections to shielded or coaxial cable. Also, a terminal crimped onto the stranded wire to allow insertion into terminal blocks.


A rubber seal used on the cable side of multiple contact connector to seal the connector against moisture, dirt or air.


A group of wire and cables, usually made with breakouts. Furthermore, with a rubber or plastic sheath tie them together. A harness also provides interconnection of an electric circuit.


A material that offers high electrical resistance making it suitable for covering components, terminals, and wires. This material also helps to prevent the possible future contact of adjacent conductors and a resulting short circuit.

Insulation Crimp

Area of a terminal, splice or contact formed around the insulation of the wire.


An outer covering, usually nonmetallic, mainly used for protection against the environment.


A device attached to certain connectors that permit uncoupling and separation of connector halves by a pull on a wire or cable.

Multiple-Conductor Cable

A combination of two or more conductors cabled together and insulated from one another and from sheath or armor where used.


A mechanical arrangement of inserts and/or shell configuration that prohibits the mating of mismatched plugs and receptacles.

RF Connector

Connector used for connecting or terminating coaxial cable.

Ribbon Cable

A flat cable of individually insulated conductors lying parallel and held together by means of adhesive film laminate.

Strain Relief 

A technique or item which reduces the transmission of mechanical stresses to the conductor termination.

Stress Relief

A predetermined amount of slack to relieve tension in component or lead wires.


A device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another conductor, etc., to establish an electrical connection. Some types of terminals include ring, tongue, spade, flag, hook, blade, quick-connect, offset and flagged.


A tube of extruded non-supported plastic or metallic material.


Slender rod or filament of drawn metal.

Wire Diameter

The overall conductor plus insulation thickness.

Types of Wire Terminals 

The definition of a terminal is:

A device designed to terminate a conductor that is to be affixed to a post, stud, chassis, another tongue, etc., to establish an electrical connection.

Wire Terminals come in many different shapes and sizes. This is due to the size of the wire and screw. Also, there are several types of terminals.

Wire Harness Manufacturing Terminals Include:

  • Ring
  • Spade
  • Hook
  • Quick-disconnect
  • Bullet
  • Butt terminals
  • Flagged

Wire terminals are available in insulated and non-insulated. The insulation provides a protective cover. Therefore, serving as a non-conductor. Furthermore, the type of project that is being done will determine if you need insulated or non-insulated terminals.

The insulation spares the wire from water and moisture as well. Also, it protects against extreme heat or cold. Wire insulation is typically available in vinyl, nylon and heat shrink.  Non-insulated terminals provide much more economic value with its low cost. Also, they are commonly used when extra protection is unnecessary.

When purchasing various Types of Wire Terminals, make sure that your purchase meets industry standards as well as project requirements.

Wire Terminals

Ring Terminals

Types of Wire Insulation

A ring terminal is a round-ended terminal that easily allows a screw or stud to be attached. Ring terminals also called ring connectors, come in various sizes. It is crucial that the ring terminal is compatible with the wire gauge and stud size. Ring Terminals are either crimped or soldered to the wire. Available in insulated or non-insulated.


Spade Terminals

Spade Terminals are also called spade connectors or fork terminals due to the shape of the terminal. A spade terminal is available in various sizes depending on the gauge of the wire and stud size. Additionally, the open-ended spade terminal is convenient to use allowing easy attachment or removal from the screw. Especially for wire harness projects that are tight on space for installation. They are also available in insulated or non-insulated.


Hook Terminals

Similar to the Spade Terminal, Hook Terminals are convenient to use with an open end (imagine a tiny version of Captain Hook). These terminals are produced as insulated or non-insulated. Hook Terminals offer a simplistic yet durable connection for a variety of projects.



Quick-Disconnect Terminals

A quick-disconnect terminal provides convenient and reliable usage while also offering an easy connect and disconnect between two wires. They are commonly found in auto, industrial and consumer products. Products can be insulated or non-insulated. Quick-Disconnect Terminals additionally deliver a stable and durable connection.


Bullet Terminals

Types of Wire Terminals

Bullet Terminals (also called bullet terminals) make an easy, reliable and secure connection. It is simple to disconnect as well. Bullet terminals also connect with the male and open-ended round female connectors creating a high-quality connection. Therefore, the connection with bullet terminals helps prevent corrosion and other potentially harmful materials from entering a wire harness.


Butt Terminals

A Butt Terminal connects or terminates single or multiple wires. Butt Terminals help prevent abrasion and cutting. Additionally, this extra protection helps keep out moisture, corrosion, and other negative elements. Butt Terminals serve as a simple solution to extend wires due to the ability to mate and connect wires. Simply install each wire on the open end of the connector, then crimp both ends of the terminal to secure the connection.


Flagged Terminals 

Flag Terminals also called flag connectors to offer a convenient and secure connection. Flag terminals work well in tight spaces as well as when a quick-disconnect is too large. Provides a quick and easy connection and disconnect. Also available in insulated and non-insulated.


Wire Insulation

Wires can be found… seems like… everywhere. Any electrical product that demands a current flowing will typically require a wire (or cable). Even when you hear something is “wireless”. In this instance wires power the device sending a signal. Electricity traveling through wires bring each of us tremendous joy and pleasure.

Examples of electronics containing wires:

  • Computers
  • Internet routers
  • Also, music players (MP3 and iPods)
  • Communication devices (Cell Phones)
  • Vehicles
  • Appliances

Actually, can you imagine surviving a single day without electricity? Well, in the early stages, electricity did not travel so safely through wires. Thankfully electricity travels safe and sound through wires protected with wire insulation.

Wire Harness Manufacturing

The explosive growth of electrical products well over a century ago drastically increased the use of wires carrying electricity. Unfortunately, uncovered or exposed wires were responsible for dangerous situations.

Furthermore, exposed wires led to electrical shocks or fire. However, the addition of a non-conductive cover was a brilliant move to protect and strengthen wires. The application of Wire Insulation protects wires greatly reducing potential hazards and threats.

You can take a look at wire insulation in the 19th century.

Check out this cool video on porcelain insulators. Thanks to Thomas Edison Tech Center.

 Wire Insulation Evolution

Due to increasing demand, electrical products require a solution to protect wires. The solution is affordable and efficient. Also, with the early growth in popularity, wire harness assembly has become necessary. It is much more efficient in harnessing loose wires. This is opposed to a “free for all”. Especially for electrical consumer goods and the auto industry. Both of which have exploded since the early 20th century.

Insulation serves as a non-conductor. The Insulation also separates and protects wires within a wire harness assembly. Especially since it is a nasty world out there with many detrimental elements that can cause harm to non-insulted wires.

To save the day, an insulated jacket protects each wire from the elements keeping the wire cozy and safe. Like insulated terminals, wire insulation also protects from moisture and extreme temperatures.

Thankfully wire insulation today is much more efficient. It is also, effective and affordable.  For example, thermoplastic high heat-resistant nylon coated wire (THHN wire) is low in cost. It is also lightweight. Due to these factors, it is an extremely popular wire insulation option.

Now that you know all about terminals and wires you need to know how they come together to create a wire harness.

Crimping Tools

We have over 30 years of wire harness manufacturing experience. Also, we here at Falconer Electronics have accumulated an impressive arsenal of crimping tools. When crimping wires and cables for our customers we have to utilize the proper tools. These allow our team to execute jobs with accuracy and efficiency. As well as, in a safe manner.

Many projects require crimping wires by hand. When producing wire assemblies for prototypes and small volume runs, handheld crimping tools sure come in…well… handy.

It is extremely important to look over the entire assembly when selecting the proper tool. For example, a basic pliers-style crimp tool can fit various wires, connectors, and terminals. Also, matching the right size tool is imperative when terminating wires.

A great brand is Molex. They are a global leader in the manufacturing of high-quality electrical tools. They are also a leader in components and other equipment. Falconer Electronics hax relied on Molex for many years. We trust their products.

The team at Molex declares they solve challenges “through our collaborative process, we take a multi-dimensional approach that brings together engineers, product designers, and manufacturers to ensure the design cycle is smooth and seamless.”

Below is one of the “Bad Boys” from Molex that our team loves to use when tackling tough projects:

Pneumatic Crimping Tool

Not interested in crimping wires by hand? Or do you have a large amount to crimp? No problem. Pneumatic crimping tools are extremely beneficial and efficient. Additionally, a pneumatic tool allows you to work hands-free due to air power. These tools are also fast and accurate. All qualities that will drastically increase your production.

We recently welcomed a new addition to our team. The Pneumatic Crimping Press pictured below. The “Plug’n Play” Pneumatic Press looks fierce, doesn’t it? It is ready and raring to CRIMP!! Especially ideal for wires requiring interchangeable crimping dies:

Tips for Successful Wire Harness Manufacturing 

  • The crimp does not break the insulation.
  • Also, the crimp fully wraps around and supports insulation (also cannot expose an opening greater than 45 degrees).
  • Insulation does not have puncturing to the point where tabs penetrate the wires.
  • Crimp tabs are in contact with the top of the insulation.
  • Insulation is flush with the crimped wire.
  • Additionally, identifying damaged insulation that reveals wires.
  • The wire, connector, assembly process, as well as insulation, are all compatible.

Wire Harness Manufacturing

Wire Harness Manufacturing: Crimping Wires Do’s & Don’ts

The IPC/WHMA-A-620  standard provides the necessary guidance on crimping wires. Consequently, this standard shows what is acceptable along with what is considered defective. Here are a few examples of Do’s and Don’ts:


  • Insulation crimp tabs fully wrap and support insulation
  • Additionally, the insulation fully enters and extends past the insulation crimp tabs
  • Wires must be in solid working condition – also cannot have scrapes, nicks, severing or other damages
  • The connector retains the wires
  • Center the crimp indent
  • Insulation crimp must provide a minimum side report of 180 degrees


  • Wires should not have deformities- Flattening untwisting, buckling, or kinking
  • Insulation should not show any signs of pinching, pulling, fraying, discoloration, or charring
  • Also, the insulation crimp needs to fully support and wrap insulation without causing any damage or breaking the insulation
  • No broken insulation- This can expose wires causing safety issues and potential hazards
  • Wire not secured by crimp
  • Contact has visible cracks and fractures
  • Also, no Birdcaging – Wire Separation

These are just a handful of the requirements.

To learn more about the Wire Harness Manufacturer’s Association and A-620 Standards, please click here.

Wire Harness Manufacturing Quality Control  

Wire Harness Quality Control is paramount at Falconer Electronics. We perform testing on cables and wire harness assemblies for every order. Therefore, quality control strongly impacts the bottom line with the wire harness assembly process. Also, our well-guided wire harness quality control and a solid test system prevents unnecessary errors, stress and lost profits.

High accuracy during the assembly process is the key to maintaining competitive pricing and reliability. We take every step to ensure accuracy at the time of assembling and producing the wires. Instituting a strict wire harness quality control system during production brings significant benefits to our customers.

Wire Harness Manufacturing Testing Check List

Safety First! Wire Harness Testing requires extreme caution. This is due to it involving live wires. Unfortunately, electric shock and burns can turn a great day into a really bad day quickly. It is mandatory to use personal protective equipment on the job such as safety glasses when testing a wire assembly.

When performing Wire Harness Testing, our quality control department strictly follows the IPC/WHMA-A-620 Standard. Most importantly, this standard is a collection of visual Quality Acceptability Requirements for Cable as well as Wire and Harness Assemblies.

Wire Harness Manufacturing Checklist for Testing Wires:

  1. Accurate Labeling
  2. Check for Damaged Insulation or Defective Wires
  3. Continuity
  4. Correct Wire Gauge
  5. Also, Check for Proper Crimps
  6. Free of Moisture and Corrosion
  7. Optimum Wire Placement Within Connectors
  8. Pull Test
  9. Test for Broken Wires
  10. Finally, Test for Shorts

Deming Values for Continual Improvement

Going old school, we are also big fans of 20th-century management guru Dr. Deming. Dr. W. Edwards Deming created 14 points for management with a quest for continual improvement. Especially since Dr. Deming is credited with being the master of quality improvement. Particularly with his work in Japan during the 1950’s.

The Deming Institute continues the incredible legacy of Dr. Deming.

Furthermore, one of the core values at the Deming Institute states:

We are dedicated to the Deming philosophy and the belief that working together, with humility, we can make a difference in the quality of life for everyone.

This is a truly inspiring message!

According to Dr. Deming, implementing the 14 points is a philosophical way of conducting business with an unwavering quest for continual improvement. In addition, new tactics and behaviors become habits. Furthermore, those habits eventually form into the core beliefs and culture of a company.

In particular, two interesting points from Dr. Deming’s 14 points that help drive our wire harness quality control:

1. Create constancy of purpose toward improvement of product and service, with the aim to become competitive and to stay in business, and as a result to provide jobs.

5. Improve constantly and forever the system of production and service, to improve quality and productivity, and thus constantly decrease costs.

Consequences when continual improvement and quality are NOT the top priority:

  • High defect rates
  • Underutilized equipment
  • Poor productivity
  • Poor inventory management
  • Safety concerns
  • Finally, low morale with employees

Dr. W. Edwards Deming

Wrapping it Up 

In conclusion, at Falconer Electronics, Wire Harness Manufacturing runs through our veins. Consequently, having built literally millions of Wire Harnesses over the past 30+ years. Actually many of our employees say they could build a wire harness in their sleep. (Is that why they started bringing their pillows to work?)

However, on a serious note, Wire Harness Manufacturing drives our business. Furthermore, delivering consistent and high-quality Wire Harness Assemblies contributes greatly to our successful long-term customer relationships dating back to 1985.

Thank you for reading our post on Wire Harness Manufacturing Terms, Tools, and Tips of the Trade.

Also, for more information on Wire Harness Manufacturing, click here:

For additional information click on the links below:

Lastly, connect on Facebook, Twitter, and LinkedIn for more electronic info.



Made to order ground straps

Bonding and ground straps are terms that people often make the mistake of using interchangeably. However, they are not the same thing. While their jobs are similar in nature there are very important differences. Also, their functionality is almost opposite to each other.


In this particular example, bonding means attaching two pieces of metal from a machine to connect them permanently. Joining these pieces creates an electrical path between the two pieces. Therefore, the two metal pieces (and in turn their machinery) will have the same electrical potential. Another example of bonding would also eliminate electrical buildup between two machines.

The main reason for bonding within electrical equipment is to ensure the safety of workers. If a person connects two pieces of machinery there is a potential for electrical shock. However, if there is bonding between the two pieces there should be a protection to anyone interacting with the machines.  The bonding of electronics also works with the grounding of those electronics.

Ground Straps

To continue on with the above example, you will have to ground the metal components or equipment after bonding. You accomplish this by attaching a ground strap to components while also attaching the ground strap after the bonding process. With this method, once the ground strap is attached to ground and all the other metal components are bonded together they would all be at the same ground potential.

Even when there is bonding between two machines there should also be a ground to a neutral point like the earth or another piece of material that has already been through the grounding process. Ground straps are a tool used for this. As stated in our blog on the uses of ground straps, ground straps are important because they protect people and electrical devices from electrostatic discharge (ESD).

If a short circuit occurs a ground strap will redirect the electrical charge to a ground as opposed to allowing it to travel through a person who is interacting with the machine. As well as protecting people, a ground strap can also protect any other machine from the shorted-out circuit. A ground strap will provide a safe route for the electricity to travel rather than going into another machine and causing a chain reaction of shortages.

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To order any of our Ground Straps you can go to our ground strap page

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For more info on electronics manufacturing, please connect with us on TwitterGoogle+, and LinkedIn.

Let’s talk Heavy Duty Ground Straps! Not just any type of Ground Straps.

We mean HEAVY DUTY Ground Straps. Hard Core. Fierce. Down and Dirty. Rugged. Tough as Nails. Relentless. Tenacious.

Climbing Mount Everest…..without any oxygen….type of Heavy Duty Ground Straps.

Hall of Fame Linebacker Heavy Duty Ground Straps: Think Dick Butkus, Mike Singletary, and Brian Urlacher (for all of the Bears fans out there). Jack Lambert and Lawrence Taylor type of tough (for the non-Bears fans).

Running A Tough Mudder……backward……in ski boots……on a 100-degree day………without water………….being tasered the entire course….while also being chased by pit bulls…….. type of tough.

We are talking, “Grandma Would Be Proud of You” Type of Heavy Duty Ground Straps.

Buy Heavy Duty Ground Straps Direct & Save!

No Middle Man! Definitely No Additional Markups! Therefore, why buy retail when you can purchase directly from the manufacturer?

We make’em & ship’em. Quick!

With 33 years experience serving Fortune 500 Companies. Mid-size manufacturers. Small business owners.  As well as everyone in between, our team tackles any project.

Need 1 or 500,000? No problem.

Custom Orders? Absolutely.

Blanket Orders? We would be happy to.

Wide Selection of Heavy Duty Ground Straps

Heavy Duty Ground Straps

These Heavy Duty Ground Straps are corrosion resistant. Furthermore, the tinned copper braided wire offers durability, flexibility and maximum conductivity.

For your convenience and fast service, we offer a line of in-stock Heavy Duty Ground Straps. Currently, our stock lengths include 4, 8, 12, 16 and 20 inches.

Also, custom sizes and terminals available as well. We like to tell our customers, “Any Size for Any Job!” Therefore, we would love to discuss your project. Especially challenging jobs. 

In addition, you are always welcome to utilize our FREE WIRE HARNESS ESTIMATOR.

Made in the USA 

Take advantage of the tremendous benefits when purchasing Heavy Duty Ground Straps Made in the USA:

  • Low Minimums: Avoid the huge financial risks that go along with purchasing large quantities with importing
  • Short Lead Times and Quick Turnaround (No ocean to cross when you buy domestic)
  • Avoid the Hassle of Clearing Customs
  • Eliminate Unnecessary Duties and Import Fees
  • Also, Improve Inventory Turnover
  • In Addition: No Letter of Credit Needed
Agile and Flexible 

Furthermore, our customers value and appreciate the agility and flexibility offered when buying directly from the manufacturer. We consider ourselves an extension and partner of your business.

  • Free samples available upon request
  • Fast Turnaround
  • Highly Skilled and Experienced Team
  • Buying power that lowers your costs
  • Multiple shipping options also reduces your costs
  • In addition to our near perfect customer satisfaction levels
  • All Due to our 33 years of experience

Finally for more info on electronics manufacturing as well as all of the other fun things happening at Falconer Electronics, please check out our blog here.

Also, please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIC DAY!




Groundhog Day! A wonderful time of year. Ski and snowboarding season is still at full throttle. Yet, the whispers of spring are just around the corner.

Not to mention, a reminder of one of our favorite movies of all time, Groundhog Day. A classic film with Bill Murray that came out 25 years ago in 1993. Where did that time go? If you are not familiar with this timeless treasure, do yourself a favor and watch it soon. Being Groundhog Day, no time better than the present.

Groundhog Day: A Shocking Experience 

Well, Groundhog Day is also a perfect time to kick off our series on staying grounded with ground cords and ground straps. In other words, keeping safe. Always remember safety first.Groundhog

A toaster in the tub? Of course, not a good idea. Water and electricity are typically not friendly to each other (understatement of the day). As a matter of fact, any electrical device in the tub will be a shocking experience. Not in a pleasant way though.

Electrical currents love to travel, fast. The human body does not serve well as a carrier of electric currents. Wires, on the other hand, they LOVE electrical currents flowing through them. Think of all of the many benefits that electrical currents offer.

Electrical currents keep our homes warm, rooms lit with proper lighting, refrigerators running, microwaves heating and…well….you get the idea. The device that you are reading this with has wires inside that are tidily tucked away out of harm’s way.

No plans for the weekend? No problem. Make a nice cup of hot chocolate. Grab milk out of the fridge, mix with cocoa and heat up on the stove. Throw a bag of popcorn in the microwave. Settle in for a Winter night with Bill Murray and Groundhog Day on your TV or tablet. It is a great day to appreciate ALL of the electricity flowing safely through your home keeping you warm, nourished and entertained.

Lastly, just remember, spring is just around the corner. The Groundhog says so.

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

Braided Ground Straps

You’re Grounded! Typically not a welcomed expression. Especially during those tough teenage years. Well, when discussing Braided Ground Straps, “You’re Grounded” means safety and dependability. 

Electrical currents power the world. Can you imagine life without electricity? Wow! How on earth did our poor ancestors survive without it?

However, electrical currents deliver a powerful force. Unfortunately, without the proper safety and precaution, dangerous and unwanted results can occur.

Grounding an electrical current prevents shocks as well as further damage (even fatalities – ouch!). Braided Ground Straps serve as an incredible safety resource. Check out last weeks blog post for further discussion.

Buy Braided Ground Straps Direct & Save

Now, you can now purchase Braided Ground Straps direct from the manufacturer. Falconer Electronics assembles high-quality Braided Ground Straps for various industries.

Do you like saving money? We hear you yelling at the computer, “Absolutely!”

Since you love saving money, take advantage of the tremendous savings by purchasing directly from the manufacturer.

Any Size for Any Job

Available in a variety of sizes. The common width that our customers pursue includes 1/4″ as well as 1/2″. Each Braided Ground Strap is topped off with an uninsulated ring terminal.

Braided Ground Straps are heavy duty and corrosion resistant. The tinned copper braided wire offers durability, flexibility and maximum conductivity.

A solder dipped ring terminal terminates each end. Also, terminals are infused with RoHS solder to improve performance and tensile strength.

Stock lengths include 4, 8, 12, 16 and 20 inches.

Custom Sizes & Terminals Available

Need a custom size or another terminal configuration? We are happy to help!

Please call or email to discuss your project needs….OR…..You are also welcome to utilize our FREE WIRE HARNESS ESTIMATOR.

This is another new tool to make life easy for our customers. Simply enter the requirements for your Braided Ground Strap and you will receive an estimate immediately via email.

In addition to the Wire Harness Estimator, feel free to Submit a Drawing. Especially since we love exploring new projects.

American Made with Over 100 Years Experience 

Lastly, production of all Braided Ground Straps takes place at our facility in Falconer NY. Our dynamic Wire Harness & Cable Assembly team delivers well over 100 years of experience to your project.

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


ground straps

 Braided Ground Straps

What are Ground Straps?

The purpose of ground straps are to protect people and electrical devices. Ground straps protect from electrostatic discharge (ESD). These straps reroute electric currents to a safe ground. As a result, they will protect any person who interacts with that particular electrical device. Due to providing a ground for electricity to travel in the situation of a short circuit, ground straps have the potential of saving lives.


Why Do You Need Ground Straps?

Why is grounding important? Consequently, in the instance of a short circuit within an electronic device, the electricity needs to go somewhere. Therefore, if a person is working with or on the specific device the electricity will potentially go through that person. This will result in injury or even death.

Furthermore, a ground strap provides a designated path for the electrical energy. This path leads to the safety of the ground. It is better for it to go into the ground instead of traveling through any person in proximity to the electricity.

Also, these straps can prevent electrical damage. As a result, any other devices can be affected. Therefore, this occurs if they are attached to the shorted-out device. As long as the electricity has a safe route to take away from devices or people there shouldn’t be any damage or injury.


Different Types of Ground Straps


  • Braided
  • Mesh or grid
  • Sheet or strip
  • Solid Wire

Material Types:

  • Aluminum
  • Copper
  • Tinned copper
  • Stainless steel
  • Nickel-plated materials
  • Finally, Silver-plated materials
Uses of Ground Straps

A Braided Ground Strap fits multiple tasks. These tasks include bonding, straps, grounding or connecting moving parts. Furthermore, we have listed a number of grounding applications below:

  • Automotive and Heavy Duty Truck
  • Electrical Panel Doors and Enclosures
  • Engines and Motors
  • Generators
  • Machinery and Equipment
  • Power Supplies
  • Solar Panels
  • Transformers

To learn about wire harnesses check out our page! Also, check out our wire estimator. You can design your own custom wire harnesses.

For additional information on the wire harness assembly process, please click the links below:

For more info on electronics manufacturing, please connect with us on Twitter and LinkedIn.