Wire Harness Estimate

Do You Need a Wire Harness Estimate, Pronto?


Need a price on a Wire Harness Assembly, like RIGHT NOW?! Traditionally, receiving a Wire Harness Estimate could take hours or even days. Well, thanks to some hard work and innovation that problem is now solved. You can now receive a Wire Harness Estimate within minutes (or even seconds depending on how fast you type). Stop by and check out the brand new Falconer Electronics Wire Harness Estimator.

Wire Harness Estimate in 6 Simple Steps 

The Wire Harness Estimator offers you a simple 6 step process. With each step, you can easily enter product information. Once complete, you hit submit. Within seconds your Wire Harness Estimate will be waiting for you in your email box.

Wire Harness Estimate

  1. Select your wire
  2. Enter the number of wires
  3. Select your terminals
  4. Choose add-ons – such as sleeving, heat shrink, labels, or wire ties
  5. Don’t see an item you need – this step you can type in a request
  6. Submit

At any time you are also free to submit a drawing.

Creating a prototype?

Testing a new product?

Need a Wire Harness Estimate quick? No problem. You can breeze through the Wire Harness Estimator completely free of charge and no obligations.

Questions on Wire Harness Components? Click here.

Custom Wire Harness Assembly 

What type of industries do we serve? Our wire harnesses can be found in the healthcare industry, auto and truck lighting, heating systems, locomotive products and much more.  

Commercial Power Strips

Commercial Power Strips manufactured by Falconer Electronics can be found working relentlessly at numerous major brick and mortar retail stores at product displays. We produce our own wire harnesses for all of our power strips.

Portable Work Lights 

We even produce wire harnesses for our own proprietary product line of portable work lights. This line includes magnetic trouble lights and magnetic spotlights.

MLC-50-C3 Trouble Light


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

Supplies Components

Who Supplies Components When Outsourcing Production? – Part 7


Supply or not supply? That is the question for today.

When outsourcing to a custom manufacturer, a common question occurs, “Who Supplies Components When Outsourcing Production?” Do you supply your own parts and materials or is it more cost-effective for the custom manufacturer to purchase materials? We will address this topic from the perspective of a Wire Harness Manufacturer

This is our continued series on Outsourcing Wire Harness Manufacturing. Below includes links to previous topics on this discussion: 

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 

Interviewing a Wire Harness Manufacturer – Part 4

Discreet Questions to Determine Character Compatibility and Financial Viability – Part 5

Touring a Wire Harness Manufacturer – Part 6

What if I want to supply my own products such as wire, connectors and other components to save money? 

Supplying your own products to a custom manufacturer offers several positives and negatives. It works best to communicate clearly with the manufacturer on the pros and cons of either option. 

The question is do you really save money?  One-size fits all does not apply here. There are many variables to consider which option makes the most sense (or more importantly – make the most CENTS). 

Pros and Cons 

Let’s take a look at the Pros and Cons of supplying your own parts and components: 


Several benefits fall in your favor by taking the initiative to order and supply your own parts when outsourcing: 

  1. You control the ordering process and supply chain. 
  2. Ordering your own parts allows you to have full disclosure of pricing on the cost of goods. 
  3. First-hand knowledge of availability or stock-outs on your product. 
  4. Better control over delivery times. 
  5. Negotiate your own discounts with the vendor. 


Ordering or supplying your own parts may be welcomed by the manufacturer. On the other hand, this approach could be disruptive to the manufacturer. Here are a few negatives to consider: 

  1. The time you spend ordering parts. 
  2. The time you spend coordinating deliveries. 
  3. Lost opportunity of volume discounts available to the manufacturer due to their purchasing power.
  4. Product knowledge and expertise that the manufacturer possesses.
  5. The variety of shipments arriving at manufacturer at different times throws off their production schedule for your product. 
  6. The receiving department at the manufacturer must be informed of delivery. This communication is crucial for the manufacturer in order to properly schedule production of your products. 
  7. The manufacturer must implement a means to monetize the receipt of your goods that you order. It is in neither parties interest to not account for labor, handling, and the overhead expense of receiving and storing goods. 

Supplies Components

An important question to ask yourself: Is your time better spent focusing on other areas of the business? Did you partner with a company that you trust enough to delegate the purchases to the custom manufacturer? 

You partnered or hired the custom manufacturer due to their proficiency, expertise, and ability to deliver a quality product on time. Is it worth your time, hassle and energy to locate new vendors and product in areas that are either new to you or where you are lacking purchasing power and strong vendor relationships?

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

Touring a Wire Harness Manufacturer – Part 6


Part 6! We almost feel like the Harry Potter Series (my daughter would be proud of that analogy). Each week we have been addressing the due diligence and selection process when deciding to outsource wire harness manufacturing. Today we will explore taking a tour of a custom manufacturer. In particular, Touring a Wire Harness Manufacturer.

Below includes previous topics on this discussion: 

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 

Interviewing a Wire Harness Manufacturer – Part 4

Discreet Questions to Determine Character Compatibility and Financial Viability – Part 5

It is Now Time to Plan a Visit and Take a Tour

So you continue plunging through the due diligence process to select a custom manufacturer. 

You have performed dozens of Google searches to narrow down the field.

You have evaluated plenty of websites and social media pages until they all start to blend together.

Hopefully, several companies are standing out from the crowd. 

Emails have been exchanged and phone calls have been made to break the ice.

There may be one or two that really seem like head and shoulders above the rest.

You are feeling good. 

It is now time to plan a visit and tour each facility. 

A physical visit to top candidates in person is vital with your decision. You might even want to consider a surprise visit (“Hey, I was in the neighborhood” – even if 500 miles away). 

Here is an excellent article from the Harvard Business Review regarding plant tours (Even though this was written 20 years ago):

Eyes Wide Open and the Attitude of a Harsh Critic

It is extremely important to go into the tour with eyes wide open and the attitude of a harsh critic.

(Actually, this was just a great excuse to get Judge Judy into one of our blogs).

What to Look for When Touring a Wire Harness Manufacturer

Below is a list to consider when Touring a Wire Harness Manufacturer: 

  1. Do you find the building and property presentable or unkempt? (Unmowed grass, disheveled parking lot, garbage, broken windows, etc…) 
  2. Office presentable or unkempt? (Top of the line everything or dated to the 1960’s) 
  3. Are you warmly greeted?
  4. Management, staff, and employees pleasant and welcoming?
  5. Do employees look happy and hustling?
  6. Are tools and equipment organized and well maintained?
  7. Are the warehouse and inventory efficiently organized?
  8. Is the Shipping dock clear of clutter?
  9. Are you impressed or underwhelmed with the team and operation? 
  10. Are there any red flags that make you uneasy?
  11. Do employees have cell phones out?
  12. Check kitchen area – is it clean or organized and dirty? 
  13. Are restrooms clean?
  14. Are there any key employees that do not come out to meet you? 
  15. Evaluating the quantity and quality of staff, does the company seem to be top heavy? 
  16. What are the years of service of the management team?
  17. Be prepared with tough questions regarding your product and process to determine if they are indeed experts in their field.
  18. Is the management team short and brief with you? Is this a good sign that they are focused and busy or are they rude and distracted? 
  19. On the other hand, if they meet with you for a long period are they too lackadaisical or not busy? 
  20. Do they seem eager to earn your business or desperate? 

Outsourcing your product production to a custom manufacturer is similar to finding quality daycare for your child. You need to find a company that you Trust, Trust, Trust! 

There is a saying that if something is not a “HELL YAH” then it is simply a “No”. 

Check back next week for Part 7 of our series on Outsourcing. 

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

Wire Harness Estimator Components Defined


Falconer Electronics, Inc recently announced a new tool, the Wire Harness Estimator, to assist with determining the cost of a Wire Harness Assembly (click here to view).

The Wire Harness Estimator allows you to quickly and easily enter the components that make up your wire harness and within seconds you will receive an email with the estimate. 

Below you will find helpful definitions as a guide to use the Wire Harness Estimator. 

Wire Types And What They Are Used For

Stranded: When a wire needs to be flexible within a product.

Flexible Ground Braid: Grounding connection between two terminals while still having the ability to move or vibrate.

Ribbon Cable – Gray: Usually used to make connections within electrical devices such as computers, DVD players, or hard drives.

THHN – Solid: For a fixed application like traveling through straight formed conduit.

THHN – Stranded: For an application where a flexible wire is needed, as when placing wire around corners or in power boxes.

Wire Gauges And How They Are Defined

Wire Gauges We Offer:

22, 20, 18, 16, 14, 12, 10, 8, 6

Figure 1.1

Physical Size of Wire:

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 22 gauge wire is much smaller in size than a 6 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. 

The smaller the wire gauge the less current that is traveling through the wire itself. Also meaning the smaller gauged wires have less amperage they can handle. 

Figure 1.2 (Kingway)

Wire Colors And What They Are Used For

Black: Hot/ Positive

White: Common/ Negative

Green: Ground

Red: Secondary Line: Hot/Positive

Blue, Yellow, Brown: Available for customer’s personal choice to connect one point to another.

Terminal Types And Why They Are Needed

Ring Terminal: To connect two points through a wire and is attached with a screw. Figure 2.1

Fork Terminal: Much like that Ring Terminal it connects two points through a wire and is attached with a screw, however it is also useful if you need to remove the terminal from a device because of its open ended design. Figure 2.2

Quick Connect / Disconnect Terminal: Terminals that attach to another terminal by sliding into place. There are female and male connecting terminals. Figure 2.3 and Figure 2.4 

Ferrule Terminal: Fastening, joining, sealing, or reinforcing wires to each other. Can be used in many different applications due to the many different types there are. Figure 2.5


Figure 2.1              Figure 2.2         Figure 2.3        Figure 2.4     Figure 2.5

Terminal Insulation Type And Why They Are Needed


  • Partially Insulated- Usually on ring or fork terminals. Used mostly to prevent crossing/ shorting of the wires by preventing contact with other wires.
  • Fully Insulated- Mostly on Quick Connect/ Disconnect terminals. Fully insulated terminals are mostly used to prevent contact between terminals. Therefore the wires would not be in contact with each other in small spaces. 

Uninsulated- Terminals that need to be crimped in place or soldered in place. Usually, are finished with heat shrink tubing.

Terminal Stud Sizes And Why It’s Important To Know What Size You Need 

Terminal Stud Sizes We Offer:

2,4,6,8,10, 1/4″

                                                       Figure 3.1 

Why is the terminal stud size important:

If your assembly requires that wires are attached by screws or other hardware you need to be sure that you have a proper size to fit the hardware you are using.

Therefore if you are using a 1/4″ screw in your assembly but you have gotten a #2 terminal stud you won’t be able to attach your wire to your assembly. As you can see in Figure 3.1 the sizes are very different.   

The other important thing to remember when looking at terminal stud size is they have to be able to fit around your screw or hardware. This means that a 1/4″ terminal stud will actually be slightly larger than a 1/4″.  

Wire Harness Add-Ons And What They Are Used For

Spiral Wrap: Bundles wires together while still providing flexibility

Wire Ties: Bundling wires into separate groups, separating wires from other wires in harness, or holding a wire into a specific direction

Shrink Tubing: Protecting and insulating wire from outside elements


For more information on our wire harnesses check out our Wire Harness page.

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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.