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Wire Gauge

Tips for Choosing the Correct Gauge of Wire for the Job

Have you been looking into a wiring project? Do you know what gauge of wire is best suited for your needs? Our tips can help you in the choosing process of wires!

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**

1: What type of project are you doing?

There are many different types of wiring projects. Depending on whether you are working on home wiring or building your own robot, there is a difference of what type of wire is required. For example, some projects include:

  • Home wiring
  • Robotics
  • Computers
  • Vehicles

2: How much space do you need for wiring?

To begin with different housings for different projects will vary in size. Due to the wire size, the space needed to house them will vary. If you think about a light switch, some have a single switch and therefore only need enough room for the wires of that one switch. However, there are light switches that have multiple switches. Therefore, the space required for the wiring of a multi-switch receptacle is larger than that of a single switch receptacle. In order to do a job properly, you need to be aware of how much space you have to work with and really need. If you are working on home wiring that requires a larger current as opposed to a robot that requires less current the space needed is different because the wire size will be different.

3: How are wire gauges calculated?

Especially relevant is the fact that as wire increases in physical width, the gauge of that wire will decrease in numerical value. While this does seem backward it’s really not. Due to the wire drawing process, the number of operations that it takes to get it to that physical size is the numerical gauge of a wire. As a result, gauges are larger or smaller than the physical size.

Wire Gauge

4: What are large and small gauged wires used for?

There are also many different gauges of wire. Consequently, they have many different uses.

Uses for some smaller gauges (larger physical sizes) of wire:

  • Electrical lines (like those you see outside attached to power lines)
  • Heavy duty automobiles like trains, larger armored trucks
  • Home wiring

Uses for some larger gauges (smaller physical sizes of wire):

  • Computers
  • Radios
  • Phones
  • GPS
  • Mp3 player
5: How much amperage do you require?

There are different factors that determine the required amount of amperage:

  • Amperage= Wattage/Volts
  • What current do you need for your project
  • Where the wire is going
  • Where the wire is coming from

In addition to these tips you can learn more about wire gauges by looking back to our previous blog Why Do Wire Gauge Sizes Seem To Work Backwards?

In conclusion, the chart below will be helpful in deciding which wire is appropriate for your specific job.

AWG Cable/ Conductor Size Chart

AWG Diameter 
[inches]
 Diameter 
[mm]
Area
[mm2]
Resistance
[Ohms / 1000 ft]
Resistance
[Ohms / km]
 Max Current 
[Amperes]
Max Frequency
for 100% skin depth
 0000 (4/0)0.4611.6841070.0490.16072302125 Hz
000 (3/0)0.409610.40384850.06180.202704239160 Hz
00 (2/0)0.36489.2659267.40.07790.255512190200 Hz
0 (1/0)0.32498.2524653.50.09830.322424150250 Hz
10.28937.3482242.40.12390.406392119325 Hz
20.25766.5430433.60.15630.51266494410 Hz
30.22945.8267626.70.1970.6461675500 Hz
40.20435.1892221.20.24850.8150860650 Hz
50.18194.6202616.80.31331.02762447810 Hz
60.1624.114813.30.39511.295928371100 Hz
70.14433.6652210.50.49821.634096301300 Hz
80.12853.26398.370.62822.060496241650 Hz
90.11442.905766.630.79212.598088192050 Hz
100.10192.588265.260.99893.276392152600 Hz
110.09072.303784.171.264.1328123200 Hz
120.08082.052323.311.5885.208649.34150 Hz
130.0721.82882.622.0036.569847.45300 Hz
140.06411.628142.082.5258.2825.96700 Hz
150.05711.450341.653.18410.443524.78250 Hz
160.05081.290321.314.01613.172483.711 k Hz
170.04531.150621.045.06416.609922.913 k Hz
180.04031.023620.8236.38520.94282.317 kHz
190.03590.911860.6538.05126.407281.821 kHz
200.0320.81280.51810.1533.2921.527 kHz
210.02850.72390.4112.841.9841.233 kHz
220.02540.645160.32616.1452.93920.9242 kHz
230.02260.574040.25820.3666.78080.72953 kHz
240.02010.510540.20525.6784.19760.57768 kHz
250.01790.454660.16232.37106.17360.45785 kHz
260.01590.403860.12940.81133.85680.361107 kHz
270.01420.360680.10251.47168.82160.288130 kHz
280.01260.320040.08164.9212.8720.226170 kHz
290.01130.287020.064281.83268.40240.182210 kHz
300.010.2540.0509103.2338.4960.142270 kHz
310.00890.226060.0404130.1426.7280.113340 kHz
320.0080.20320.032164.1538.2480.091430 kHz
330.00710.180340.0254206.9678.6320.072540 kHz
340.00630.160020.0201260.9855.7520.056690 kHz
350.00560.142240.0163291079.120.044870 kHz
360.0050.1270.0127414.813600.0351100 kHz
370.00450.11430.01523.117150.02891350 kHz
380.0040.10160.00797659.621630.02281750 kHz
390.00350.08890.00632831.827280.01752250 kHz
400.00310.07874 0.00501104934400.01372900 kHz

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

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

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

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

**Always have electrical projects looked over by professionals before any installation or use to prevent injury or fire**   

Positive Work Environment

Never bet against a company dedicated to creating a Positive Work Environment. A deep commitment to innovation combined with maintaining a healthy entrepreneurial spirit are driving forces that can enable a small business to achieve great heights. Having fun while at work makes an enthusiastic workplace and a dynamic team.

A Positive Work Environment Increases Productivity 

According to the Harvard Business Review, a Positive Work Environment is more productive. In the article, “Proof That Positive Work Cultures Are More Productive“, the authors share that work stress significantly reduces the health and productivity of employees. Absenteeism, disengagement, and lack of loyalty all dramatically increase costs and hurt the bottom line. 

Deliberate actions allow a company to create a dynamic culture, which includes ambition, competitiveness, creativity, flexibility, enthusiasm, and initiative. Combining these efforts with the ability to take risks and bear responsibility is a winning formula. Many large companies founded by visionary leaders begin as a start-up enterprise and eventually evolve into an industry powerhouse.

Positive Work Environment

 Southwest Airlines Positively Outrageous 

Ever fly on Southwest Airlines and have a stewardess serenade the audience while giving out the flight instructions? Southwest Airlines has produced 40 straight years of profits in an industry that continuously suffers massive financial losses and has been littered with bankruptcies over the years.

Southwest lives by a daily mantra to never accept status quo tracing back to its founder, Herb Kelleher. He pointed out that it is extremely difficult for a competitor to imitate a company’s success. According to an article in Forbes, Kelleher states,“They can buy all the physical things. The things you can’t buy are dedication, devotion, loyalty—the feeling that you are participating in a crusade”.

Whistle While You Work  

Taking a tour of Falconer Electronics displays hard working Americans dedicated to producing high-quality commercial outlet stripsprinted circuit boards, and wire harnesses. You will hear machines running, trucks rumbling, computers cranking and other sounds of great products being produced.

More importantly, you will hear lots of laughter. Our team has a wicked sense of humor. You can always hear someone laughing over something hysterical. Either a goofy event that occurred over the weekend with a friend or family member. A crazy pet story brings a good laugh as well around here. Work hard and laughing harder is our mantra!

Our office is located near Wegmans Food Markets which provides an excellent role model for small businesses. Fortune ranked Wegmans as the #2 Best Companies to Work For in 2017. This year marks the 20th straight year landing on the Fortune 100 Best Companies to Work For list. Wegmans institutes a thriving Positive Work Environment that combines fun with professionalism to deliver outstanding customer service. This winning formula proves hugely successful and profitable with Wegmans celebrating 100 years in business. 
 
Thank you for reading our post on a Positive Work Environment.
 
Please connect on FacebookTwitterGoogle+LinkedIn, and Pinterest for more electronic info.

Discreet Questions to Determine Financial Viability When Outsourcing – Part 5

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

This post is Part 5 of our series on Outsourcing Custom Manufacturing Operations. In particular, Outsourcing Wire Harness Manufacturing Processes.

Previous 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

Interviewing a Wire Harness Manufacturer – Part 4 

Discreet Questions Can Save You Down the Road 

So you have entered the interview process to select a new custom manufacturer to partner with. Now you are digging deeper in 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 crucial, 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?

Below are a number of discreet questions that you could ask that would potentially reveal any red flags for you. 

Discreet Questions

Prior Outsourcing Experience – That Ended Poorly 

This blog is being written from a poor previous experience with outsourcing services to a fulfillment center. There were many warning signs. Actually, what is above warning signs? Shots fired across the bow? 

We would pay the company tens of thousands of dollars each month which was paid on our credit card. On two separate occasions, the company ran our credit card twice, on the same day. The first time seemed like a simple mistake. “Oops, our credit card processor must have processed the card twice. So sorry. We will issue a refund.” Which they eventually did, many days later. 

The second time, same excuse but now had our team gravely concerned. To make matters worse, it was discovered that the property and liability insurance had not been paid. Needless to say, the relationship ended very poorly. We moved out at a huge expense. The fulfillment center went out of business so after. Even though we thankfully dodged a major disaster, this was a painful and expensive lesson. 

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?
  • 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? 
Discreet Questions to 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:

  1. Strike up a conversation on hobbies. Do they have expensive hobbies: Golf at Pebble Beach, mountain climbing the Himalayas, scuba diving off the Thailand, flying a helicopter, Yacht, own a collection of Ferrari’s, etc… 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”, find out their neighborhood and drive by or if you are not nearby look up on Google. This will let you know their lifestyle.
  4. Ask for bank references 
  5. ……business references 
  6. ……character references
  7. ……customer references
  8. Google the owner to discover any past felonies, convictions or other bad news. 
  9. Check their Facebook page – see what they do in their personal time. 
  10. Check other social media – Twitter, Snapchat, Instagram, and Pinterest.
  11. Look for Videos on YouTube.
  12. Check mutual connections on LinkedIn. 
  13. Seek out mutual professional connections and casually start asking around for any character concerns.  
  14. Take a physical tour of the company and facility – look for any warning signs.
  15. Meet with company supervisors.
  16. Casually speak with as many employees as possible to get a gauge on the owner/management and conditions of the company.
  17. Look for matching or mismatched priorities – expensive office furniture, overstaffed, excessive non-business essentials (foosball table, games, kegs, etc).
  18. Get a gauge on morale at the company.
  19. Does the owner wear an expensive wardrobe or jewelry?
  20. Last, ask the owner for an opportunity to have a mutual meeting with their accountant to view audited financials. Even offer to have the meeting at your expense. 

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

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

New Wire Harness Manufacturer

How to Find a New Wire Harness Manufacturer – Part 3

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Trying to Find a New Wire Harness Manufacturer? You have landed on the right place. As a Custom Wire Harness Manufacturer since 1985, our team at Falconer Electronics has worked with hundreds of customers ranging from many different industries. 

This blog post continues our series on maximizing the due diligence process when searching for a new custom manufacturer to outsource production. In particular, partnering with a New Wire Harness Manufacturer. Each week we are providing a helpful step by step process to provide guidance with your search. 

Previous posts include: 

Outsource Your Wire Harness Assembly Process – Part 1

Selecting a Wire Harness Manufacturer – Part 2

This week we discuss the process of discovering a New Wire Harness Manufacturer. 

How to Find a New Wire Harness Manufacturer? 

Partnering with to a New Wire Harness Manufacturer would be extremely beneficial for your company. Once you have decided to outsource your Wire Harness Assembly process, now the search begins. 

Unless you already have a candidate in mind, most likely you will kick start the 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 or other local connections and business organizations 
  5. Trade Associations

If you lack successful connections going this route, no fear. Call on your dear friend Google. Conducting a few Google searches will show you local and national Wire Harness Manufacturing companies. 

Is geography a critical factor? For example, if you were looking for a supplier of wooden pallets, you need somebody extremely close otherwise shipping costs would be brutal and cost prohibitive. 

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

Once you have discovered a worthy prospect, begin conducting company research to see if this is a good fit for you. 

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. Proximity? Do they need to be within a certain distance of your facility? 

Check out their Social Media:

  1. Is the company active on social media and 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 are a few questions to consider asking: 

  1. Types of customers – What industry does the company target? Do they understand your needs? Can they speak your language? Do you feel a chemistry and kindred spirit with this company? Do they have the flexibility to speed up when during your busier times? Can they adjust to varying seasonal demands? 
  2. Vendor relationships – Do they have outstanding vendor relationships? Do they have purchasing power? Are they willing to negotiate and fight for the lowest cost on product for you? Do they have strong cash flow and pay their bills on time so there are no delays in purchasing your product? 

New Wire Harness Manufacturer

Next week with our series on selecting a New Wire Harness Manufacturer to partner with, we will dig further into questions that you can ask during the interview process. 

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

Outsource Your Wire Harness Assembly Process – Part 1

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Is it Time to Outsource Your Wire Harness Assembly Process? 

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

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

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

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

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

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

Wire Harness Assembly Process

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

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

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

Start With Performing an Internal SWOT 

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

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

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

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

Partnering with Seasoned Professionals 

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

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

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

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

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

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