Posts

Many small manufacturers in the U.S. struggle to determine if the product that they assemble, manufacture or produce truly qualifies for the labels “Made in USA” or “American Made”.

Made in USA, American Made

Complying with American Made Standards

The world is shrinking fast. Competition is fierce. In addition, the internet has escalated a true global economy. Every country fights rigorously for consumers to purchase their products.

Consumers commonly make buying decisions based on labels. An important label includes country of origin. For example, U.S. manufacturers proudly label their products with “American Made” or “Made in the USA”. “American Made” represents quality products and lends a strong selling point for the product.

Unfortunately, there is confusion behind the definition of “American Made”. As a result, manufacturers in the U.S. are eager to comply with the “American Made” or “Made in USA” standards. Especially, as long as the standard is consistent and well defined.

Yet, some companies are too eager to capitalize on the “American Made” logo that actually do not qualify. Therefore, an “American Made” standard helps prevent those companies from just throwing a sticker on any product. Specifically, those that do so while disregarding its true origin.

What Does “All or Virtually All” Mean?

A Google search for “Complying with Made in the USA” produces 854,000 results. Furthermore, the #1 ranking is a link to the Federal Trade Commission website. The article is titled: Complying with the Made in USA Standard. The page offers a link to a pdf that dates back to 1998. However, it is still relevant today. This pdf states:

Traditionally, the Commission has required that a product advertised as Made in USA be “all or virtually all” made in the U.S.

“All or virtually all” means that all significant parts and processing that go into the product must be of U.S origin. That is, the product should contain no — or at least negligible — foreign content.-Federal Trade Commission pdf

So what does “or at least negligible” actually mean?

Manufacturers may think that they are truly making American products with all domestic suppliers. However, certain parts or raw material may be imports from a foreign country. All unbeknownst to the manufacturer.

Even if you purchase raw materials, parts, and components from a domestic distributor, those products may have originated in another country.

Manufacturers have to be aware of all aspects of their products. However, this can be a difficult undertaking. When you purchase components from a vendor they will not always provide you with the origin of those pieces. This is especially true if there is a larger component that has hardware or other parts that form the component as a whole. This is the situation that California manufacturer Maglite found themselves in.

Manufacturer Responsibility

As an example, Maglite, a California lighting manufacturer made national news. They lost a lawsuit over false “Made in USA” claims. Maglite is committed to American manufacturing and an amazing American entrepreneurial success story (click for video from ABC News). However, the lawsuit boiled down to a microchip and a rubber seal. Both of which had origins overseas. Therefore, costing the owner thousands of dollars in legal defense. Meanwhile, they still lost their case.

Check out this clip from CNBC (click here).

Unfortunately, in this case, the responsibility fell on the manufacturer. Like many manufacturers, they felt they were playing by the rules but fell short according to the court of California. Also, ignorance is not a reliable excuse or defense. There are companies that find themselves in trouble even when intentions are honest and genuine.

The Best Intentions

Manufacturers may have the best intentions of purchasing domestic goods. However, these products are not always available. Specific countries, geographical regions, climates, and many other factors affect the production of certain products in those areas. You may have a product that you assemble in the U.S. Production of that same product could occur with raw components originating from various countries.

In many cases, it is just not cost-effective to produce certain products in the U.S. Basic economics says that supply and demand control a market. Price is typically a key ingredient. What if the production of a product isn’t at a price that a customer is willing to pay? It is going to be extremely challenging to create a product that will sell. It will also be hard to sustain a profitable company due to the lack of interest in your product. Well at this point you are thinking, thank you Captain Obvious.

How Can You Protect Your Business?

One of the main ways to protect your business from lawsuits like that Maglite experienced is to be aware of your sourced parts. Also, before claiming your product is “Made in America” be aware of the laws in your state.

Why would the state you’re in make a difference? Different states have different definitions of “American Made”. Unfortunately for Maglite, California has one of the strictest definitions in the country (click here). Other states, however, acknowledge that there needs to be some leeway when it comes to hardware.

In Maglite’s case the components they got in trouble for were not available in the United States at the time. Maglite had done searches for that product and came up empty handed. That is another issue that manufacturers need to be aware of. When a component is not available in the U.S. what do you do? Also, how can you still receive the “Made in America” Stamp?

What if You Can’t Find Your Components in The U.S.?

Unfortunately, there are not many options. Depending on the component you may be able to employ a local business to manufacture the part for you. If your business is lucky enough to have ties to another manufacturer that would be willing to help, you are then all set. There is also the possibility of you manufacturing the piece yourself. The plus side to this is you would know exactly where the piece came from.

However, what if this isn’t an option? This is a very real possibility. There may not be an option of creating your own part. Whether due to time constraints or available resources. In this situation, you will need to find another way.

What if the only option is to import that specific part like Maglite had to? This is when you need to be aware of your state’s specific laws on the matter. If you are lucky enough to be in a state that has wiggle room depending on the component you may be able to import what you need without penalty.

However, if you are in a state with strict laws (like Maglite) you may have no choice then leaving off the “Made in America” label.

According to an article in the Daily Bulletin, Maglite hopes for a federal bill on the “Made in America” standard. A federal bill would certainly level the playing field as well as clarify the definition.

How Do You Still Represent Your American Workforce?

Do not lose all hope in that situation! There are other labels that you can use that will still encourage customers to buy your product. Some of these labels include:

  • “Assembled in America”
  • “Contains –% American Product”
  • “Final Product Assembled in the USA”
  •  also “USA Factory Assembled”

Each of these labels still encourage loyal customers and patriotic sales. Customers will see one of these labels and know that they are purchasing a product from an American Factory. Furthermore, with these labels and others like them, you can represent your American workforce and still be in compliance with the law.

Connect with Us

To learn more about Falconer Electronics, you can check out information on our American Made Ground Straps and Wire Harnesses.

Also, click on these links to learn more about our Wire Harness Estimator and our new Ground Strap Express!

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

 

 

Wire Harness Estimate

When it comes to gathering a wire harness estimate and quote from various suppliers, the process can cause a lot of frustration. Slow response times from vendors negatively impact your deadlines. Furthermore, it can impact your credibility with customers. Delays also hurt profits.

Therefore, our goal is to save our customers as much time and money as possible. As a Wire Harness Manufacturer, many of our customers commented that they would love a tool where they could capture a Wire Harness Estimate immediately. Right Now!

 

We all have the same 24 hours in a day. There are no competitive advantages over time. Time is money. Especially since you have thousands of tasks to conquer during each work day. Maximizing efficiency is crucial to your success.

So we went to work with our programmer to create a solution. In particular, a solution that would provide a Wire Harness Estimate as quickly as possible.

The result:

The FEI Wire Harness Estimator 

Receive Your Wire Harness Estimate Instantly 

The FEI Wire Harness Estimator offers an instant Wire Harness Estimate. Perfect when seeking a Wire Harness Estimate or when you just need a ballpark price, pronto.

The brand new online FEI Wire Harness Estimator allows buyers, product designers, and engineers the ability to enter the specs of a wire harness assembly quickly and easily. This straightforward approach eliminates the need to wait days or even weeks for pricing out your estimate.

This tool also works perfectly for companies building a prototype or new product design. As discussed in our New Product Development Series, gathering product information and pricing is critical to moving your project forward.

Fast & Easy to Use 

The FEI Wire Harness Estimator delivers an estimated cost of your wire harness assembly within seconds of submission. It arrives directly to your email. Therefore, you can utilize the simplistic step by step process down below to select each item you require for your wire harness.

First, you can select:

Additionally, are you looking for connectors or other items, not on the list? No problem! All you need to do is enter the manufacturer part number. The FEI Wire Harness Estimator adds that item to the Wire Harness Estimate.

Lastly, you can finalize your estimate with any add-ons you need. Extras such as a spiral wrap, expandable sleeving, wire ties, heat shrink, labels, and flags can all be added.

No Commitments & No Obligation 

There is no commitments or obligations for you to purchase your harnesses from us.

The only requirement is your name and email address. After you fill out all of the required steps you will instantly receive an email with your estimate.

However, the Wire Harness Estimate does NOT represent a formal quote. Yet, this is an outstanding opportunity to provide a shortcut for you to capture a Wire Harness Estimate or a ballpark price for your new Wire Harness Assembly.

Also, for detailed pricing on quantity breaks or a formal quote, you are welcome to submit a drawing and a request for proposal. Afterward, a team member from Falconer Electronics will contact you with an actual quote fitting your timeline and quantity.

You can also call 716-665-4176 or email [email protected] with any questions. We have specialists to walk you through the process.

Furthermore, there is NO MINIMUM requirement and we welcome customers of all sizes. Therefore, you do not have to be part of a large company or even plan on making a large order. We encourage orders of any size.

Step by Step Guide to the FEI Wire Harness Estimator

Below offers a step by step process when using the FEI Wire Harness Estimator:

Step 1) Select Wire Type 

Wire Harness Estimate

SELECT YOUR UNCUT WIRE (or wires):

You may select multiple wires – Click “Add to Estimate” after each selection.

Options include:

Wire Stranded

  • Available Colors – Black, White, Green, Red, Blue, Yellow, Brown
  • Available Gauges – 6, 8, 10, 12, 14, 16, 18, 20, 22

Flexible Ground Braid 

  • Uninsulated
  • 1/4″ and 1/2″

Ribbon Cable – Gray

  • Available Color – Gray or Color-coded
  • Conductor – 10, 14, 16, 20, 26, 40

THHN – Solid 

  • Available Color – Black, White, Green, Red, Gray, Orange
  • Available Gauge – 12 Gauge Only

THHN – Strand

  • Available Colors – Black, White, Green
  • Available Gauge – 12 Gauge Only

Select Length – The TOTAL length of wire required for a single assembly – This also applies for multiple wires. Select the length of each wire.

Click “ADD TO ESTIMATE”.

The Estimator allows you to Add multiple wires.

Review your selection – if ready to proceed – click “NEXT STEP”.

 

STEP 2) Select the Number of Individual Wires 

Wire Harness Estimate

This section will include the TOTAL number of Individual Wires in your Wire Harness Estimate.

Click “NEXT STEP”

STEP 3) Select Your Terminal 

Wire Harness Estimate

This section allows you the opportunity to select a specific manufacturer part number. Therefore, enter the manufacturer part number in the space provided and hit SEARCH. Furthermore, the product will populate into the Wire Harness Estimate.

Therefore, if your specific part number is not available, you may select from the list of “house” parts below:

  • Ring Terminal
  • Fork Terminal
  • Quick Connect/Disconnect Terminals
  • Also, Ferrules Terminal

Select Quantity (for a Single Wire Harness)

Click “ADD TO ESTIMATE”

In addition, you may add multiple terminals and hit “ADD TO ESTIMATE” each time

Click “NEXT STEP”

 

STEP 4) Select Add-ons 

Wire Harness Estimate

  • Spiral Wrap
  • Expandable Sleeving
  • Wire Ties
  • Heat Shrink
  • Wire Labels
  • Wire Flags

Enter Length in inches or Quantity for all of the above as is applicable.

Click “ADD TO ESTIMATE”

Also, you may add multiple Add-ons in this section. Also, please remember to hit “ADD TO ESTIMATE” after each selection.

Click “NEXT STEP”

 

STEP 5) Component Request 

Wire Harness Estimate

Furthermore, this section allows you the opportunity to add any other components or helpful notes that will help determine your Wire Harness Estimate.

Also, any items added to the “Components Request” section will NOT be added to the initial estimate. Therefore you will receive a separate email including the additional components to your Wire Harness Estimate.

 

STEP 6) Review and Submit 

Wire Harness Estimate

 

Lastly, the Summary page allows you the opportunity to review your entries and make sure that everything looks accurate.

Additionally, once you are satisfied with your selection simply enter your name and email address. You may also enter a project number to help keep track of each Wire Harness Estimate.

Finally, enter the correct number for the captcha and hit SUBMIT. Finished!

Finally, you will receive your Wire Harness Estimate within seconds in your email box.

Let’s Connect

Thank you for reading our blog on “Instant Wire Harness Estimate: Your Step by Step Guide.”

For additional information on Wire Harness Manufacturing, please check out these posts:

Also, please connect with us on the Falconer Electronics Inc websiteFacebookTwitterGoogle+, and LinkedIn.

Wishing you an ELECTRIFYING DAY!

Prototype

Prototype! A well working Prototype!

To continue our series on New Product Development by building “Building a Better Mousetrap”, let’s explore creating a prototype.

When starting out with a brand new product, perfecting a working model is crucial. Yet, establishing a fully functioning prototype does not necessarily guarantee success. Building a sustainable business model is equally as important.

All Products are in the Prototype Stage

Here is an interesting thought to consider: Every product that exists is in the prototype stage. Just some prototypes have already hit the market. Even stayed on the market for an extended period of time. That is until a “Better Mousetrap” came along.

What are you talking about, you ask?

Here is an example to consider. Kodak film was in working prototype stage….for decades. Actually over a century. A massive success. Then digital photography came along and replaced it. The prototype of print film finally succumbed to a new technology, digital photography.

The brutal irony is Kodak invented digital photography in 1973.  By a 24 year old Kodak engineer named Steve Sasson. Kodak didn’t take the new innovation of digital photography serious though.

How could they? Digital photography would slaughter the golden calf. Destroy the cash cow. Or any other bovine reference you prefer. Millions upon millions of annual Kodak profits would be jeopardized had they embraced digital photography.

Fast forward, Kodak no longer rules the photography market. Especially shocking considering Kodak served on the Dow Jones Index over 70 years from 1930-2004. As a matter of fact, anyone under the age of 20 (out side of Rochester NY) has probably never even heard of Kodak.

How About Crackberry?

Another example of a prototype that hit the market with great success, then disappeared was Blackberry. Blackberry initially dominated the market with cutting edge smart phones. It was even compared to one of the highest addictive drugs on the planet being called the “Crackberry”. Customers could not put it down. Until Apple came along with a better prototype. A “better mousetrap”. The iPhone.

There are millions of examples of products that never make it to market. Kodak and Blackberry demonstrate sad examples of working products that once dominated an industry can disappear in a blink of the eye. Product development is a tough business.

Minimal Viable Product = Working Prototype

So what does that mean to an inspiring inventor? An overly confident entrepreneur who has an exciting new product? How can you ensure success?

Start with making sure your product works. Works extremely well. Create a solid working prototype.

As we discussed previously, establish an all-star team to guide you to success. Starting with finding a quality electrical engineer.

A prototype proves your idea and concept. It solidifies the viability of your product. Eric Reis in his blockbuster book, “The Lean Startup” discusses bringing the MVP to market. A Minimal Viable Product.

Before spending tens of thousands of dollars on a patent, make sure that your product works. More importantly, that consumers (outside of immediate friends and family) are willing to part with their hard earned money to pay you for this exciting new product.

Below is an outstanding video from Google on prototyping:

Thank you for reading our blog as we continue our series on new product development.

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

Wishing you an ELECTRIFYING DAY!

 

Building a Better Mousetrap That is Profitable 

“If You Build a Better Mousetrap, the world will beat a path to your door.” American philosopher, Ralph Waldo Emerson is credited with that famous line from the nineteenth century.

Better Mousetrap

However, as legend has it, he never said those exact words. Ralph Waldo Emerson actually stated the following:

“If a man has good corn or wood, or boards, or pigs, to sell, or can make better chairs or knives, crucibles or church organs, than anybody else, you will find a broad hard-beaten road to his house, though it be in the woods.”

“Build a Better Mousetrap” just sounds catchier and flows easier.

Anyway, as the point remains, build a better product above the competition and customers will line up. Profits will pour in. If it were only that easy though.

Building a better mousetrap is a massive accomplishment. Creating a sustainable and profitable business model is a whole other story.

Side note: If you enjoy reading inspirational books and want to go “old school”, check out Ralph Waldo Emerson’s “We Are the Builders of Our Fortunes: Success through Self-Reliance.” Especially if you need a motivational boost with your new product. We strongly recommend it.

95% Fail or 5% Success

Creating and inventing a new product is tough. The process is certainly not for the weary. According to Harvard Business Professor Clayton Christensen, 30,000 new products are launched each year. Of those, 95% of new products fail! That is a crazy statistic.

You may actually face better odds of survival going over Niagara Falls than successfully establishing a new product.

With such a high fail rate, why do inventors and innovators even attempt to fall in the successful 5%?

Ego? Delusion? Determination? Fame and fortune?

Typically everyone thinks they have created the “better mousetrap”. Surely, no one goes into new product development expecting to join the 95% failure club.

To be successful, you need to put the odds in your favor by exhausting due diligence. Gathering every resource in your corner to achieve success.

Persistence and Determination  

Over the years, we have worked closely with a wide variety of companies that have internally engineered new electrical products (better mousetraps).

Areas that our team focuses on include the following: Wire Harness Assemblies. Ground Straps. Commercial Power Strips. Printed Circuit Boards.

We have made lots and lots of prototypes for customers over the years. Throughout our experience, a common phrase heard from engineers, “Going back to the drawing board”.

Yet, this just means that the person or company continues striving for perfection. Making the PERFECT mousetrap.

From our experience, persistence and sheer determination are two ingredients required to launch a successful product.

We thought you might enjoy this quick video explaining the “Build a Better Mousetrap” concept:

Finally, as you strive to bring your “better mousetrap” to market, surround yourself with experts that contribute greatly to your cause. Seasoned veterans who have been there before. Trained guides familiar with the challenging terrain. Individuals committed to your success.

Thank you for reading our post on “Building a Better Mousetrap”. This blog kicks off our series on developing a new product in electronics. Please check back each week for more info.

Let’s Connect

To learn more about Ground Straps and the Wire Harness Assembly process, please click on the links below:

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

 

Custom Cable Harness Estimator Picture - Custom Wire Harness Estimator Ribbon

The History of Ribbon Cables

 

The Early Years

The Ribbon Cable was first discovered in 1956 by Cicoil Corporation. Its original design was to be flat to fit into computers. They were to replace the large and inflexible cables. Engineers were able to figure out a way to use liquid silicone rubber to mold a very thin flat cable. They also contain multiple conductors of the same size, controlling the spacing of each internal copper wire. The Flat Cable allowed companies like IBM, Sperry/Univac, Honeywell, GE and NCR to replace bulky, stiff round cables with sleek, flexible ribbon cables.

Custom Cable Harness Estimator Picture - Custom Wire Harness Estimator Ribbon

In addition, in the 1960’s NASA was in need of a mission-critical, lightweight cable. Cicoil’s Cables met all of the rigorous requirements for a Space Flight Cable. As a result, the cable harness helped America put a man on the Moon. As a result, the lightweight Ribbon cables were integral to the first American Orbit of the Earth, first Space Walk in 1965, and the Lunar Landing in 1969. In addition in 1998, a new extrusion process allowed manufacturers to continuously produce lengths of flat cable.

Today

Today, Ribbon Cable comes in all different shapes, sizes, and colors. They are also in a huge range of applications. From high-speed computer connections with coaxial cable to rainbow cable. Many different methods and materials go into simplifying and reduce the cost of these cables. The standardizing of the design and spacing of the wires and the thickness of the insulation. They could also be easily terminated through the use of insulation displacement connectors. Finally, the simplicity of the cables, their low profile, and low cost due to standardization allows ribbon cables to be in computers, printers, and many electronic devices.

For more information on where to find these colorful cables and their uses, Check out next weeks blog!

Connect with Us

To Get a Personalized Estimate for Ribbon Cables Visit Our Wire Harness Estimator

Follow us on our Facebook page!

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

 

Wire Harness Manufacturer

Welcome to today’s discussion on outsourcing. In particular, outsourcing your wire harness assemblies for a critical project. Finding yourself in the beginning stages of searching for a new Wire Harness Manufacturer to partner with presents several  challenges. Let’s go on a buyer’s journey to help assist you with the selection process. 

Reasons to Outsource to a Wire Harness Manufacturer

First, outsourcing to a Wire Harness Manufacturer gets you in the game immediately without adding significant overhead and fixed costs.

Establishing the wire harness assembly process as a variable expense lends tremendous value and flexibility to your growth and profitability. This allows you to eliminate the financial risks of taking on the exorbitant investment required to build your own wire harness department.

In order to create your own wire harness assembly department, you would need a designated area in your facility. That is if you actually have the space to conduct these tasks.

Your next step requires purchasing all of the proper equipment, machinery, and crimping tools. This investment adds up quickly. Even into the tens or hundreds of thousands of dollars.

Having a properly trained staff in place is another major investment of time and resources. For example, crimping wires safely and accurately requires extensive experience and a specialized skill.Wire Harness Manufacturer

Top 10 Tips for Selecting a Wire Harness Manufacturer

So if this sounds unrealistic and overwhelming, you need to consider what steps are necessary to find a Wire Harness Manufacturer that will serve as a trusted partner.

You now might be asking yourself:

  • Where do I begin my search?
  • What type of questions should I ask when interviewing a Wire Harness Manufacturer?
  • How can I determine that this Wire Harness Manufacturer is a solid fit with our company culture
  • and goals?
  • Is this a trustworthy candidate?

Well, we have you covered. Below is a 10 step process to consider when outsourcing to a Wire Harness Manufacturer.

#1

Is it Time to Outsource to a Wire Harness Manufacturer? 

“Should we begin outsourcing our Wire Harness Assemblies to a Wire Harness Manufacturer?”

This is 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.

If you have been asking yourself if it is time to outsource to a Wire Harness Manufacturer, 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 your internal Wire Harness Assembly Process became a burden is an important step.

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

#2

Reasons to Start Looking  

Serving as a Wire Harness Manufacturer for over 30 years, we have found several scenarios where a customer approaches us for the first time. Typically the customer contacts us with excitement (or out of frustration) when they are Selecting a Wire Harness Manufacturer.

Let’s role play. Below are a few scenarios where a new customer finds themselves seeking a new Wire Harness Manufacturer…….

Scenario #1) 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.

For example (and a shameless plug), 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. New customers love it.

Another concern with creating a prototype on your own includes the prohibitive costs. Purchasing the necessary quantities to begin the process can be cumbersome and not cost effective. A Wire Harness Manufacturer has the tools, equipment, staff, and infrastructure in place to create a prototype quickly and affordable.

Scenario #2) 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 a Wire Harness Manufacturer that best demonstrates the ability to tackle this project.

Let’s say a mid-sized manufacturer is expanding into electrical wiring.  Two examples that fit this example. We recently began working with two separate companies:

1) One that specializes in handicap accessible transportation

2) An ATM manufacturer

They each produced a new proprietary product line requiring wire harnesses and printed circuit boards. It was a significant savings for each company to outsource the wire harness assembly process and printed circuit boards rather than to attempt to conquer the project themselves.

Scenario #3) Vendor Divorce 

Unfortunately, you and your current Wire Harness Manufacturer 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 relentlessly to maintain long-lasting and monogamous marriages with our customers. We also enjoy catching new customers on the rebound.

Scenario #4) 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 into your lap to find a highly qualified Wire Harness Manufacturer. Selecting a company that you trust is essential!

This recently happened to a large customer. They found it much more cost-effective and profitable to outsource their entire line of wire harness assemblies by partnering with our staff. Our team went on full throttle to make this a smooth transition.

Try Our Custom Wire Harness Estimator

Receive an Estimate Sent Directly to Your Email Within Seconds

#3

Perform an Internal SWOT 

The next step, start with a SWOT on your internal Wire Harness Assembly process. What are the company strengths, weaknesses, opportunities, and threats? Especially if you are just starting up.  This step is critical to help determine financial risks.

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

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 Wire Harness Manufacturer that thrives and works relentlessly to gain a competitive advantage. Also, one that creates economies of scale for you. Most importantly, a solution so valuable that it just doesn’t make sense to perform these tasks on your own anymore.

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 respectively on business law, tax codes or proper insurance policies. Especially since 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. Partnering up with a Wire Harness Manufacturer that maintains an all-star team creates a winning formula. This allows you to maximize profits while minimizing risks.

#4

Where to Search for a New Wire Harness Manufacturer?

Once you determine that partnering with a New Wire Harness Manufacturer would be extremely beneficial for your company, now the fun begins.

Unless you already have a candidate in mind, most likely you will kick-start the search process by relying on connections within your network. A great place to start includes the list below:

  1. Vendors
  2. Suppliers
  3. Customers
  4. Chamber of Commerce
  5. Trade Associations
  6. Other local connections and business organizations

If you lack successful connections going this route, no fear. Call on your dear friend Google. Conducting a few Google searches will provide an array of companies that serve as a Wire Harness Manufacturer.

Is geography a critical factor? Not necessarily. Let’s say you were looking for a supplier of wooden pallets. You definitely need somebody extremely close. Otherwise, shipping costs would be brutal and cost prohibitive.

With a Wire Harness Assembly, shipping costs are typically not prohibitive and detrimental. Partnering with the right company in another part of the country can still be an effective and profitable relationship.

For example, we have customers throughout the entire U.S. We consistently ship to the west coast and Mexico as well. Shipping costs are particularly a non-factor compared to the quality of workmanship and consistently hitting tight deadlines.

Once you have discovered a worthy prospect, begin conducting company research and due diligence to see if this Wire Harness Manufacturer is a good fit for you.

Wire Harness Manufacturer

#5 

Due Diligence When Searching for a New Wire Harness Manufacturer

What can you determine from their online presence? 

Check Out the Company Website:

  1. First, explore the company website. Does the website represent the company as a partner that you can trust?
  2. Does the company reveal itself having the staff, tools, resources, and ability to tackle your project?
  3. Do they serve your industry?
  4. Do they have the experience and expertise to take on your project?
  5. Are company capabilities listed?

Check out their Social Media:

  1. Is the company active on social media with communicating their culture?
  2. Does it fit with yours?
  3. Does the company provide helpful tips?
  4. Communicate the company mission? Does the mission fit with yours?
  5. Can you easily submit a drawing of your wire harness assembly?
  6. When you contact them, do you receive a quick response?

Below includes a few additional questions to consider asking the Wire Harness Manufacturer:

  1. Types of customers they serve?
  2. What industry does the company target?
  3. Do they understand your needs?
  4. Do they have the flexibility to speed up during your busier times?
  5. Can they adjust to varying seasonal demands?
  6. Do you feel a chemistry and kindred spirit with this company?

Questions Regarding Vendor Relationships:

  1. Do they have outstanding vendor relationships?
  2. Do they have purchasing power?
  3. Are they willing to negotiate and fight for the lowest cost on products for you?
  4. Do they have strong cash flow and pay their bills on time so there are no delays in purchasing your product?

We will dig much deeper into questions to consider for your Wire Harness Manufacturer search, with #6 and & #7.

#6

Asking Challenging Questions Captures Valuable and Critical Information 

At this stage, you have narrowed the field down. To either a single or hopefully only a few Wire Harness Manufacturer candidates. Now is the 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.

 

Being overly prepared and asking the right questions can save you a great deal of grief 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. The divorce can get nasty and costly.

Having a list of tough questions prepared brings tremendous value to the process.

50 Questions When Interviewing a Wire Harness Manufacturer

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

Round I: 

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

Asking thorough 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.

#7

Discreet Questions Can Save You Down the Road 

Outsourcing manufacturing operations can deliver tremendous benefits to your business. Unfortunately, there are many risks attached as well. Furthermore, let’s continue our discussion by addressing Discreet Questions to Determine Character Compatibility and Financial Viability. Asking tough questions will help narrow down your selection process.

So you have entered the interview process to select a new custom manufacturer to partner with. Therefore, now you are digging deeper into the due diligence process to see who is exactly the best fit.

Financial stability is certainly one of your absolute top concerns. If you are both small businesses, discovering actual financial figures or intimate information may be difficult to obtain. Even though this is information is critical. Especially if the project or product represents a significant portion of your sales.

So what steps or strategies can you take to discover the financial viability of this new prospect?

Important Questions to Ask Yourself 

Here are a few questions to ask yourself through this process:

  • Does the company represent itself well?
  • Do you have similar goals and a common business philosophy?
  • Also, is this a team of people with integrity that you can trust impeccably?
  • Is this a partner that is committed to your profitability and success?
  • Or are you another opportunity for the owner to support a lavish lifestyle?

Determine Character Compatibility and Financial Viability 

Here are a number of discreet questions to consider to help determine the financial viability of the company as well as the character level of ownership:

Check Spending Habits:
  1. Strike up a conversation on hobbies. Do they have expensive hobbies? Golf at Pebble Beach, mountain climbing the Himalayas, scuba diving in Thailand, flying a helicopter, bragging about their yacht… you get the point.
  2. Find out the type of car they drive. “My spouse is looking for a new car. What type of car do you drive or recommend?”
  3. If you live near the prospect, casually ask what neighborhood they live in. Sorry to get overly “stalkerish”, but finding out their neighborhood will let you know their lifestyle. Also, Google Earth may assist.
Ask for References: 
  1. Ask for bank reference
  2. ……business references
  3. ……also, character references
  4. …… as well as customer references

Do Some Research on Google and Social Media: 

  1. Google the owner to discover any past felonies, convictions or other bad news.
  2. Additionally, you may want to check their Facebook page & see what they do in their personal time.
  3. Also, check any other social media – Twitter, Snapchat, Instagram, and Pinterest.
  4. Look for Videos on YouTube.
  5. Furthermore, check mutual connections on LinkedIn.

Going the extra mile with your due diligence process will save you a tremendous amount of grief and frustration down the road.

#8

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

So you continue plunging through the due diligence process to select a Wire Harness Manufacturer.

You have performed dozens of Google searches of “Wire Harness Manufacturer” 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.

You have also been asking plenty of tough questions and pleased with a majority of responses.

Also, there may be one or two candidates that really seem like they are head and shoulders above the rest.

You are feeling good.

Finally, it is time to plan a visit and tour each facility.

A physical visit to top candidates in person is vital to 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 on 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. Additionally, is the office presentable or unkempt? (Top of the line everything or dated to the 1960’s)
  3. Are you warmly greeted?
  4. Additionally, are the management, staff, and employees pleasant and welcoming?
  5. Also, do employees look happy and hustling?
  6. Are tools and equipment organized and well maintained?
  7. Furthermore, are the warehouse and inventory efficiently organized?
  8. Is the shipping dock clear of clutter?
  9. Also, are you impressed or underwhelmed with the team and operation?
  10. Are there any red flags that make you uneasy?
  11. Additionally, do employees have cell phones out?
  12. Check the kitchen area – is it clean and organized or dirty?
  13. In addition to the kitchen area, are the restrooms clean?
  14. Are there any key employees that do not come out to meet you?
  15. When 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 (see #6).
  18. Is the Wire Harness Manufacturer 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. Furthermore, do they seem eager to earn your business or desperate?
Bonus Round 
  1. Look for matching or mismatched priorities: expensive office furniture, overstaffed, excessive non-business essentials (foosball table, video games, keg parties, etc).
  2. Get a gauge on morale at the company.
  3. Does the owner wear an expensive wardrobe or jewelry?
  4. Finally, ask the owner for an opportunity to have a mutual meeting with their accountant to view audited financials. In addition, if necessary, offer to have the meeting at your expense. Could offer great ROI.

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

As the saying goes, if something is not a “HELL YEAH” then it is simply a “No”.

#9

Supply Parts or Not to Supply Parts?

That is the Question 

(OK, that was our pathetic attempt to sound like Shakespeare).

Anyway, a common question with new customers: “What if we would like to supply our own parts?” With many custom manufacturers, this is the equivalent of bringing your own food to a restaurant and asking them to prepare you a meal.

Supplying your own products to a custom manufacturer offers several positives and negatives. Consequently, 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?  Also, one-size fits all does not apply here. Furthermore, there are many variables to consider which option makes the most sense (or more importantly, makes the most CENTS).

Pros and Cons 

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

Positives 

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 also have full disclosure of pricing on the cost of goods.
  3. First-hand knowledge of availability or stock-outs of your product.
  4. Furthermore, you have better control over delivery times. 
  5. Negotiating your own discounts with the vendor. 
Negatives 

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

  1. The time you spend ordering parts.
  2. As well as 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. Also, the variety of shipments arriving at the manufacturer on different days 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 the production of your products.
  7. The manufacturer must implement a means to monetize the receipt of your goods that you have delivered. It is in neither parties interest to not account for labor, handling, and the overhead expense of receiving and storing goods. So, are you really saving money?
Where is Your Time Best Spent? 

Wire Harness Manufacturer

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

In addition, 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? Especially in areas that are either new to you or where you are lacking purchasing power and strong vendor relationships.

#10

Conclusion

 New Wire Harness Manufacturer  

Selecting a Wire Harness Manufacturer does not need to be a stressful process. Outsourcing Your Wire Harness Assembly can generate significant profits for your business.

Especially partnering with an experienced company with a seasoned staff. This decision lends a tremendous competitive advantage for your company. Also, selecting a Wire Harness Manufacturer that completes projects with the highest quality, effective pricing, and on-time delivery dramatically boosts to your bottom line. Therefore, teaming up with a company dedicated to your success is critical.

Wire Harness Manufacturer Checklist 

To recap, here is a checklist of company traits to pursue when finalizing your search for a new Wire Harness Manufacturer:

  1. Superior Quality
  2. Maintaining an Impeccable Customer Scorecard
  3. Also, fast Turnaround Times
  4. Competitive Prices
  5. Seasoned Staff
  6. Company Experience
  7. Short Lead Times
  8. Agile and Flexible
  9. Company Culture Dedicated to Customer Satisfaction
  10. Lastly, a Deep Commitment to Safety

Wire Harness Manufacturer

Ok. Hopefully, you are now happy as can be with your new Wire Harness Manufacturer.

Furthermore, as with any outsourcing partner, work diligently to maintain healthy and constant communication. Also, be clear about goals and expectations. This will also help guarantee a long, happy and prosperous marriage.

Thank you for taking the time to read our Tips for Selecting a Wire Harness Manufacturer.

Click on these links for more info on electronics manufacturing and ground straps.

 

Also, check out these helpful articles:

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

Wishing you a HUGELY SUCCESSFUL and an ELECTRIFYING DAY!

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.

Bonding

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.

Connect with us

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

Follow us on our Facebook page!

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

Do you know the similarities between cables and wires? Wires and cables are very similar in nature and they can have similar purposes.

The Main Similarities

The main similarities between cables and wires are that they both conduct electrical currents. Wires are the components of a cable. Multiple wires make up a single cable. Also, a single wire and a single cable both can have insulation or insulative jackets. However, a cable has an outer jacket while the single wires inside have their jackets as well. The differences in insulation can determine the different uses of a wire and cable.

Cables Cables

As stated previously, cables consist of multiple wires. There are cables that have the wires twisted to hold them together. There are also some that have the separate wires encased in an insulated jacket. This jacket doesn’t just hold the internal wires together but it also protects the internal wires from the elements. Cables can also contain numerous insulated wires. There is an extra level of protection when individual wires within a cable have their own insulation.  There is protection from corrosion and friction amongst individual wires due to the extra insulation.

Wires 

Solid and stranded are the two types of wires. Many individual strands of wire twisted together make up stranded wires. These strands can be very fine or larger depending on the application. Generally, the more strands and the smaller the strands the more flexible the wire is. Solid wire is just that, one strand of copper drawn to the appropriate gauge size. Also, wires can either be insulated or non-insulated. Insulted wires are less likely to have corrosion or the added issue of contact between non-insulated wires. A number of different applications use non-insulated wires. These applications include places where electrical wiring, armature wire, and magnet wire are needed. Non-insulated wiring is different from the insulated wire. This is due to it not being plated or coated with anything.

To learn more about Wire Harnesses Assembly click here! Free wire harness estimates are also available.

For more information on wires go to our blog!

You can also get great DIY ideas on our Facebook page! For more info on electronics manufacturing, please connect with us on TwitterGoogle+, and LinkedIn.

AWG

American Wire Gauge or AWG is the standard way of measuring wire gauges in the United States. However, in other countries, they use a different standard of measuring, SWG or British Imperial Standard Wire Gauge, for example. The availability of two different standards has led to a difference in how wire gauges are measured and what standard sizes of wire are used.

AWG

AWG is the standard for measuring wire in the United States. This standard is defined by the diameter of the electrical wire that is being measured. Therefore, it is the physical size is what matters most. Also, the larger the physical size of the wire the smaller the wire gauge according to the AWG measurements.

SWG

SWG was the legal standard for measuring wire in the United Kingdom as of 1884. All of the SWG measurements are in metric sizes. In most cases of use of the SWG measuring standard the sizes will be rounded up which does affect the accuracy.

Similarities

In a lot of ways, AWG and SWG standards are similar. Most noteworthy, both standards are based on the physical size of the wire being measured. Also, both share common wire numbers that express those physical sizes. Finally, metal measuring plates are used to determine the size of the wire.

Differences

The most obvious difference is the standard of measurements. AWG is recorded in what is referred to as the imperial system of measurement. This system of measurements is in inches. Therefore, the American standard is different from the SWG system which uses the metric system of measuring. When looking at the charts below there are slight differences in the calculations between the two systems. Especially relevant is the difference that can be seen between the 12 and 24 gauges. These are very common sizes of wire and the chart shows very drastic difference amongst the size measurements.

 

Reference charts:

AWG

wonkeedonkeetools.co

 

Wire Number
Imperial Standard
Wire Gauge
American
Wire Gauge
gauge ins. dia. ins. dia.
0000000 (7/0) 0.5000
000000 (6/0) 0.4640 0.580000
00000 (5/0) 0.4320 0.516500
0000 (4/0) 0.4000 0.460000
000 (3/0) 0.3720 0.409642
00 (2/0) 0.3480 0.364796
0 (1/0) 0.3240 0.324861
1 0.3000 0.289297
2 0.2760 0.257627
3 0.2520 0.229423
4 0.2320 0.2043
5 0.2120 0.1819
6 0.1920 0.1620
7 0.1760 0.1443
8 0.1600 0.1285
9 0.1440 0.1144
10 0.1280 0.1019
11 0.1160 0.0907
12 0.1040 0.0808
13 0.0920 0.0720
14 0.0800 0.0641
15 0.0720 0.0571
16 0.0640 0.0508
17 0.0560 0.0453
18 0.0480 0.0403
19 0.0400 0.0359
20 0.0360 0.0320
21 0.0320 0.0285
22 0.0280 0.0253
23 0.0240 0.0226
24 0.0220 0.0201
25 0.0200 0.0179
26 0.0180 0.0159
27 0.0164 0.0142
28 0.0148 0.0126
29 0.0136 0.0113
30 0.0124 0.0100
31 0.0116 0.0089
32 0.0108 0.0080
33 0.0100 0.0071
34 0.0092 0.0063
35 0.0084 0.0056
36 0.0076 0.0050
37 0.0068 0.0045
38 0.0060 0.0040
39 0.0052 0.0035
40 0.0048 0.0031
41 0.0044 0.0028
42 0.0040 0.0025
43 0.0036 0.0022
44 0.0032 0.0020
45 0.0028 0.0018
46 0.0024 0.0016
47 0.0020 0.0014
48 0.0016 0.0012
49 0.0012 0.0011
50 0.0010 0.0010
51 0.00088
52 0.00078
53 0.00070
54 0.00062
55 0.00055
56 0.00049

simetric.co

 

To learn more about American Wire Gauge measurements check out our blog WHY DO WIRE GAUGE SIZES SEEM TO WORK BACKWARDS?

For additional information on the Wire Harness Assembly Process, please click the links below:

You can also get your own custom wire harness estimate with our Wire Harness Estimator

In addition, click here for an Instant Quote on Braided Ground Straps.

Finally, let’s get social. Please connect with us on FacebookTwitterGoogle+, and LinkedIn.

Wire Harness Estimate

Need a price on a Wire Harness Assembly, like RIGHT NOW?! Traditionally, receiving Wire Harness Estimates could take hours or even days. Well, thanks to some hard work and innovation that problem is now solved. Therefore, you can now receive a Wire Harness Estimate within minutes (or even seconds depending on how fast you type). Furthermore, you should 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. Therefore, with each step, you can easily enter product information. Once complete, you hit submit. Also, within seconds your Wire Harness Estimate will be waiting for you. We send it straight to 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 –
  6. you can type in a request
  7. Finally, submit

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

Are you creating a prototype?

Do you need to test a new product?

Also, do you need a Wire Harness Estimate quick? No problem. You can breeze through the Wire Harness Estimator completely free of charge and no obligations.

Do you have 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. Also, 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. We have portable work lights. This line includes magnetic trouble lights as well as 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.

Our New Wire Harness Estimator

Falconer Electronics, Inc recently announced a new tool, The Wire Harness Estimator, to assist with determining the cost of a Wire Harness Assembly. You can check out our estimator here.

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 Their Uses

Stranded: When a wire needs to be flexible in 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 between electrical devices such as computers, DVD players, or hard drives.

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

THHN – Stranded: For an application where there is a need for flexible wire. 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 “Wire Drawing” and it looks like Figure 1.2. Therefore, “Wire Drawing” is what gives us all of the different gauges 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.

Wire Drawing

Figure 1.2 (Kingway)

Wire Colors And Their Uses

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 Their Purposes

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. Also has many different applications due to the many different types there are. Figure 2.5

Ring Terminal option on the wire harness estimator            Fork Terminal option on the wire harness estimator                       Quick Connect / Disconnect Terminal option for wire harness estimator      Quick Connect / Disconnect Terminal option for wire harness estimator    Ferrule Terminal option for the wire harness estimator

Figure 2.1              Figure 2.2         Figure 2.3        Figure 2.4     Figure 2.5

Terminal Insulation Type And Their Purposes

 Insulated

  • 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. The purpose of fully insulated terminals is 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. Are also, usually 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″

Terminal sizes

 Figure 3.1 

Why is the terminal stud size important:

If your assembly requires attachment of wires 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 a #2 terminal stud it will be impossible 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 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 Their Uses

Spiral Wrap: Bundles wires together while still providing flexibility

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

Shrink Tubing: Protecting and insulating wire from outside elements

Contact Us

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

For additional information on the Wire Harness Assembly Process, please click the links below:

Lastly, let’s get social. Please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest.

  

 

 

 

 

 

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.

 

To learn more about Ground Straps and the Wire Harness Assembly process, please click on the links below:

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

Wire Harness Estimate

Introducing the FEI Wire Harness Estimator

Falconer Electronics, Inc (FEI) proudly announces launching the brand new FEI Wire Harness Estimator. Our team is extremely excited to share this new tool with customers: https://falconerelectronics.com/custom-wire-harness-estimator/

Especially those who are eager to capture an estimate or ballpark price on their Wire Harness Assembly quickly and easily. Below offers a step by step process when using the FEI Wire Harness Estimator. 

Steps to Complete the FEI Wire Harness Estimator

 

Step 1 – Select Wire Type 

FEI Wire Harness Estimator

SELECT YOUR UNCUT WIRE (or wires): 

You may select multiple wires – Click “Add to Estimate” after each selection 

Options include:

Wire Stranded

  • Available Colors – Black, White, Green, Red, Blue, Yellow, Brown
  • Available Gauges – 6, 8, 10, 12, 14, 16, 18, 20, 22  

Flexible Ground Braid 

  • Uninsulated  
  • 1/4″ and 1/2″ 

Ribbon Cable – Gray 

  • Available Color – Gray or Color-coded 
  • Conductor – 10, 14, 16, 20, 26, 40 

THHN – Solid 

  • Available Color – Black, White, Green, Red, Gray, Orange 
  • Available Gauge – 12 Gauge Only 

THHN – Strand 

  • Available Colors – Black, White, Green 
  • Available Gauge – 12 Gauge Only 

Select Length – The TOTAL length of wire required for a single assembly – This also applies for multiple wires. Select the length of each wire. 

Click “ADD TO ESTIMATE” 

The Estimator allows you to Add multiple wires.

Review your selection – if ready to proceed – click “NEXT STEP”

 

STEP 2 – Select the Number of Individual Wires 

 

Wire Harness Estimator

This section will include the TOTAL number of Individual Wires in your wire harness assembly

Click “NEXT STEP”

 

STEP 3 – Select Your Terminal 

Wire Harness Estimator

This section allows you the opportunity to select a specific manufacturer part number. Enter the manufacturer part number in the space provided and hit SEARCH. The product will populate into the estimate. 

If your specific part number is not available, you may select from the list of “house” parts below: 

  • Ring Terminal
  • Fork Terminal
  • Quick Connect/Disconnect Terminals
  • Ferrules Terminal

Select Quantity (for a Single Wire Harness) 

Click “ADD TO ESTIMATE” 

You may add multiple terminals and hit “ADD TO ESTIMATE” each time

Click “NEXT STEP” 

 

STEP 4 – Select Add-ons 

 

Wire Harness Estimator

 

  • Spiral Wrap
  • Expandable Sleeving 
  • Wire Ties 
  • Heat Shrink
  • Wire Labels 
  • Wire Label Flags 

Enter Length in inches 

Click “ADD TO ESTIMATE” 

You may add multiple Add-ons in this section. Please hit “ADD TO ESTIMATE” after each selection. 

Click “NEXT STEP” 

 

STEP 5 – Component Request 

 

Wire Harness Estimator

This section allows you the opportunity to add any additional components or helpful notes to help determine your estimate. 

Any items added to the “Components Request” section will NOT be added to the initial estimate. You will receive a separate email including the additional components to your wire harness assembly estimate. 

 

STEP 6 – Review and Submit 

Wire Harness Estimator

 

The Summary page allows you the opportunity to review your entries and make sure that everything looks accurate. 

Once you are satisfied with your selection simply enter your name and email address. You may also enter a project number to help keep track of each wire harness assembly estimate. 

Enter the correct number for the captcha and hit SUBMIT. 

You will receive your estimate within seconds in your email box. 

 

Questions

Please call 716-665-4176 at any step of the process with questions from 7-3:30 EST or email [email protected] 

We are excited to offer this new program and welcome your constructive feedback. 

To learn more about these exciting products please connect on FacebookTwitterGoogle+, and LinkedIn,.

Wire Harness Estimator

Determining the cost of a new Wire Harness Assembly just became a whole lot easier thanks to some hard work and innovation. Falconer Electronics, Inc., (FEI) a wire harness manufacturer since 1985, proudly announces the new online FEI Wire Harness Estimator (https://falconerelectronics.com/custom-wire-harness-estimator/). 

Introducing the FEI Wire Harness Estimator

What is a Wire Harness Estimator? 

The brand new online FEI Wire Harness Estimator allows buyers, product designers, and engineers the ability to enter the specs of a wire harness assembly quickly and easily.  This straightforward approach eliminates the need to wait days or weeks for pricing out your wire harness. 

Fast & Easy to Use 

The Wire Harness Estimator delivers an estimated cost of your wire harness assembly within seconds of submission directly to your email. Utilize the simplistic step by step process as you select each item required in your assembly.

You can select your wire type, wire gauge, wire color, wire length, the number of individual wires, and wire terminals. 

Looking for additional connectors or other items not on the list? No problem! All you need to do is enter the manufacturer part number and the estimator adds that item to the estimate. 

Lastly, you can finalize your estimate with any add ons such as a spiral wrap, expandable sleeving, wire ties, and heat shrink. Wire labels and label flags can also be added. 

No Commitments – No Obligation 

The only requirement is entering your name and email address. You will instantly receive an email with the estimate. 

No commitments – no obligation. 

The estimate does NOT represent a formal quote. This is an outstanding opportunity to provide a short cut for you to capture an estimate or a ball park price for your new wire harness assembly. 

For detailed pricing on quantity breaks or a formal quote, you are welcome to submit a drawing and a request for proposal. A team member from Falconer Electronics will contact you with an actual quote fitting your timeline and quantity needed. 

You can call 716-665-4176 or email [email protected] with any questions to walk through the process. 

No minimums required and we welcome customers of all sizes. 

Thank you so much for reading this post. We invite your constructive feedback on how the Wire Harness Estimator can help your business. 

We would love to hear from you. Please connect on FacebookTwitterGoogle+, and  LinkedIn for more electronic info.

 

 

 

Wire harnesses have the capability to connect multiple points through the use of their terminals and connectors. They can provide a channel for electrical power and even information, making the connections electronics need to function.

We use electronics every day to make our lives easier and most of them contain wire harnesses. Much like our blog 5 Things That You Didn’t Know Contain PCBs we have compiled a variety of objects that contain wire harnesses.

 

5: Trains, Planes, and Automobiles

                       Image result for automobiles

It may not be every day that you ride in an airplane or a train. However, it’s a safe bet almost if not every day you are in a car. If you are anything like the majority of people your begin hitting buttons as soon as you get into your vehicle. Whether it is the radio, the windows, or air controls all of these buttons work because of wire harnesses. Even the ignition of the car is functional due to wire harnesses. Think of how different a car ride would be without someone constantly changing the radio station or turning the heat or air conditioning up and down. Ok maybe that wouldn’t be so bad but when you’re the one doing all that it’s pretty nice.

4: Construction Machinery

They built houses and buildings before they had construction machinery, but it took a long time and a lot of man power. Now a day we get frustrated when there is road construction and we’re stuck in traffic for an extra few minutes. Without wire harnesses all of the machinery and vehicles that help do these jobs quicker wouldn’t be here. Can you imagine being stuck in traffic for weeks while they built a building? Maybe that’s a good way to not get frustrated “At least they have machinery. I could be here for days”? That’s probably not realistic.

3: Microwaves and Ovens

                          

When you need a snack or dinner cooked you more than likely turn to either the microwave or the oven. (Especially in the winter months there is nothing like a nice hot meal right out of the oven). In the days before the modern ovens and way before the microwave, meals took all day. Now we can cook a pizza in under a half an hour and it can taste just like delivery. We can also heat up breakfast in the matter of a few minutes and be on our way. None of these foods that we find convenient would be available without the wire harnesses that help ovens and microwaves have the power that we are used to.

2: Computers, Printers, and Copiers

            

Computers have made lives easier by giving us information at our fingertips as well as being a tool to accomplish many different tasks (sometimes all at once).  Where would we be without social media and email? We would all still be stuck in a world of paper cuts and actual phone calls, can you imagine? Next time you log onto your computer give a silent thank you to the wire harnesses that have made your life so much easier.   

Printers and copiers are a staple in any office space. Without them time would be wasted writing everything by hand; especially if it’s a business that needs multiple copies of the same document. Printers and copiers have come a long way with changing technology. They now have wireless options so that you can make copies without being hard wired into them. Even with the new technologies wire harnesses are still a huge part of what makes copiers and printers work.

1: Televisions, DVD Players, and Blu Ray Players

               

Think of any form of entertainment that you have that involves a screen. Now picture if none of those things existed. That’s what the world would be like without wire harnesses. Wire harnesses make televisions function even throughout their many stages of development.  Without wire harnesses, there wouldn’t be any movies or shows to watch and there wouldn’t be any Netflix!

Without wire harnesses, there would be no reason to rush to buy the latest movie because there would be no way to watch it. Yes before there was T.V. there was radio, but those radios also had wire harnesses in them to make them work properly.  Next time you pop in a movie on a rainy Saturday or bundle up for some Netflix just remember that those things wouldn’t be possible without wire harnesses.

Wire harnesses do so much to keep our everyday lives running the way that we are used to. Most people don’t know how many everyday things wouldn’t be the same.

To learn more about wire harnesses check out our blog every Wednesday for our Wire Harnesses Wednesdays.

Also check out our Facebook, Twitter, and LinkedIn.

 

  

Striving for Perfection with Wire Harness Testing 

At Falconer Electronics, Wire Harness Manufacturing and Assembly runs through our veins. Having built literally millions upon millions of Wire Harnesses over the past 30 years, many of our employees say they could build a wire harness in their sleep. (Is that why they started bringing their pillows to work?) On a serious note, Wire Harness Testing is a core process with every order. Consistent and accurate Wire Harness Testing contributes greatly to our long-term and successful customer relationships. 

Wire Harness Testing Check List

Safety First! Wire Harness Testing requires extreme caution since live wires are involved. Unfortunately, electric shock and burns can turn a great day into a real bad day quickly. Mandatory personal protective equipment on the job includes gloves and safety glasses when testing a wire assembly.  

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

Below includes a check list for testing wires in a wire harness assembly: 

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

Wire Harness Testing

To learn more about the Wire Harness Manufacturing process, click on these links: Crimping Wires and Crimping Tools.

Thank you for taking the time to read our blog post on Wire Harness Testing. To learn more about the wire harness assembly process, please continue reading our weekly “Wire Harness Wednesday” blog series. 

 

Also, click on the following links to learn more on printed circuit boardssoldering circuit boards and soldering safety tips.  

Lastly, let’s get social! Please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest for more electronic info.

 

Types of Wire Terminals When Building a Wire Harness

In a previous blog post, we light-heartedly declared ourselves as experts in matchmaking wires with wire terminals. Especially since we have been building wire harness assemblies for over 30 years. We had fun with that blog post and thought it would be helpful to dig deeper into the various Types of Wire Terminals.

Terminals are defined as “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 depending on the size of the wire and screw. Several types of terminals include ring, spade, hook, quick-disconnect, bullet, butt terminals and flagged.

Wire terminals are available in insulated and non-insulated. Determining the best fit depends on your project or usage. Wire insulation provides a protective cover serving as a non-conductor. The insulation spares the wire from water and moisture as well as 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 commonly used when extra protection is unnecessary.

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

Types of 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. 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. 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). Produced 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 use offering an easy connect and disconnect for two wires. Commonly found in auto, industrial and consumer products. Produced insulated or non-insulated, Quick-Disconnect Terminals deliver a stable and durable connection.

 

Bullet Terminals

Types of Wire Terminals

Also called Bullet Connectors, Bullet Terminals make an easy, reliable and secure connection. Simple to disconnect as well. Bullet terminals connect with the male and open ended round female connectors creating a high-quality connection. 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. 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 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.

 

Thank you for taking the time to read our blog post on the various Types of Wire Terminals. To continue reading about the Wire Harness Manufacturing process, click on these links: Crimping Wires and Crimping Tools.

To learn more about the wire harness assembly process, please continue reading our weekly “Wire Harness Wednesday” blog series.

Also, click on the following links to learn more on printed circuit boardssoldering circuit boards and soldering safety tips.

Lastly, let’s get social! Please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest for more electronic info.

 

 

Matchmaking Wires & Wire Terminals

Wires get lonely! They like to socialize and maintain good company just like the rest of us (most of the time anyway). Good-hearted wires need healthy companionship with wire terminals. For example, a nice looking wire terminal from a family of good character typically make a great match for our wires. Excellent work ethic is another necessary trait. 

After building wire harness assemblies for over 30+ years, the team at Falconer Electronics likes to claim themselves as expert matchmakers of wires and wire terminals. We match wire and terminals safely and accurately. Wires need a terminal that is strong, loyal, hard-working and dedicated. Another requirement: Wire terminals that give great hugs. Holding on super tight to their wire companions is mandatory! 

In other words, a terminal that is committed to a long-term relationship. Short-term flings or a one-night stand simply does not fly around here. We only match wires and terminals that fit as soulmates. Life partners that fight through thick and thin.

Just look at all of these happy love birds that were recently matched up:

Wire Terminals

Wire Terminals at Falconer Electronics

Types of Wire Terminals 

A terminal establishes an electrical connection by terminating a conductor or wire. When matching the right wire with the best terminal, there are several factors to consider: Wire gauge, screw or stud size, as well as the electric throughput. Therefore, it is critical that the wire and terminal can handle the measure of electricity. 

Various types of terminals include: Ring terminals –  Fork terminals – Hook terminals – Spade terminals – Insulated and Non-insulated

Insulation on a terminal provides extra protection against extreme hot or cold temperatures.  The insulation on the terminal also helps prevent dust particles or debris from creating havoc within the connection. Lastly, the insulation will serve as a protector against corrosion or moisture from having a negative impact on the connection.  

Wire Terminals

Looking for a seasoned matchmaker of wire and wire terminals? Please contact us at your earliest convenience. We Love playing cupid! 

Look each week for our “Wire Harness Wednesday” blog posts. Also, check out our blog series on LED lighting every Friday for the month of June. Follow us on Facebook, Twitter, Google+, LinkedIn and Pinterest for more electronic info. 

Wire Harness Accuracy

Can you believe that today is already the last day of May? 2017 is flying by! Well, we hope you had a wonderful Memorial Day celebrating with friends and family. As we have been posting each week, May is National Electrical Safety Month. Today is “Wire Harness Wednesday”, so we would like to address wire harness accuracy as well as problem areas to look for when wires are not working properly. 

Having created literally millions of wire harness assemblies over our 30+ year history, the team at Falconer Electronics has a keen eye for identifying trouble areas. Assembling a wire harness needs to comply with the manufacturer’s requirements such as height, length, gauge and pull test. Also, each assembly must meet industry standards such as UL or ETL. It is critical that the mechanical integrity and electrical requirements are both met when crimping wires and creating a wire harness. 

There are various challenges faced with assembling cables and wires for customers. Some wire harness assemblies can be quite basic with one wire capped with two terminals. 

Other wire harnesses bring complications with multiple wires, terminals, connectors, housing and twist ties. 

Wire Harness Accuracy

                  

 Wire Harness Challenges 

Every customer project requires Wire Harness accuracy. If you are working with a wire harness that is not working properly, there are several issues that can be causing the problem. However, there can be no damage or contact deformation. 

Pinpointing the culprit causing the failure is the first step. Some failures reveal easily and immediate while others may take some time to figure out. For example, damaged wires beneath insulation can be difficult to detect. Stress on the wires may cause damage without actually breaking the insulation. Wires carry electricity and cannot withstand a pull beyond weight limitations. Wires pulled at an excessive weight will cause breaks in the wires without damaging the insulation. Even worse, damaged or broken wires underneath a circuit board can be an extremely frustrating find. 

May is Electrical Safety Month!  Check out our Facebook page for “Electrical Fail Fridays” and “What not to do” this past month. You can also find us on Twitter and Google+.  June blog posts will include LED lighting as well as continue our series on “Wire Harness Wednesdays”.

See you then & have a Great day!!

 

The History of Wire Harnesses

Wire Harnesses

Wire Harnesses are an assembly of cables or wires that distribute electrical signals in the most efficient way possible. Cables and Wire Harnesses are bound together by straps, cable ties, cable lacing, sleeves, electrical tape, conduit, a weave of extruded string, or a combination.

In the 1920s, wire harnesses became more prominent, especially in the automotive industry. Engineers found that binding the many wires and cables into a wire harness allowed the wires and cables to be better secured against the adverse effects of vibrations, abrasions, and moisture. The 1920s also saw a boom in electrical household goods. Washing machines, Irons, fridges, vacuum cleaners all designed using many small components and connected by complex individual wiring systems. Manufacturing these products for mass production was often a timely and a costly process and by introducing pre-assembled wire harnesses, manufacturers offered a timelier more cost effective build.

           Wire Harness Assembly

Engineers design Wire Harnesses according to specific electrical requirements. A diagram is then provided for the assembly. Wire harnesses continue to be manufactured by hand, due to the many different processes involved, such as:

  • Routing wires through sleeves
  • Taping with fabric tape, in particular on branch outs from wire strands
  • Crimping terminals onto wires, particularly for so-called multiple crimps (more than one wire into one terminal)
  • Inserting one sleeve into another
  • Fastening strands with tape, clamps or cable ties

Falconer Electronics has been making wire harnesses since 1985. They are a crucial part of any electrical component.  For more information check out our Website!

To learn more about Ground Straps and the Wire Harness Assembly process, please click on the links below:

You can also find us on LinkedInTwitter and Google+.