Enquiry
You send a drawing, bill of materials or sample through the enquiry form. We prepare a quote.
Cable assemblies and wiring harnesses from Kitzingen, Germany · since 2006Every connectionthat counts.
Cable sets, wiring harnesses and sub-assemblies: designed in house with EPLAN, manufactured and tested in Kitzingen. From the first sample to series production, all from a single source.
Skip animationFrom contact to function
- 01 · Material and processing
Stripped, sealed, crimped.
The wire is stripped, the single wire seal is fitted and the crimp contact is applied by machine. Every part is chosen to suit the application.
- 02 · Contacting and connector
Contact latches, connector locks.
The contact is pushed into the housing until the single wire seal sits flush at the rear. The mating connector is then brought together and locked.
Signal pulse visualised, not a measurement
- 03 · The wiring harness
Many connections, one system.
Main trunk, branches, corrugated tube and fixing points carry power and signals to the control unit, the sensors and the loads.
- 04 · In the vehicle
From the driver’s seat to the roof.
In a municipal vehicle the wiring harness connects the control unit, the control panel, the lighting, sensors such as ABS, LiDAR and the blind spot assistant, the battery and the fuse box. They all exchange data continuously. Schematic illustration, not a customer project.
- 05 · Operation and response
One action, one response.
Press the switch: the signal reaches the control unit, its output stage switches the supply to the light, the light comes on, and the control panel reports back.
- 06 · Powertune
So that one action becomes a function.
We develop, assemble, build and test the cable systems behind it, with our own EPLAN design office, from sample to series production.
Schematic illustration · example vehicle
Powertune Spezialkabelsysteme · Kitzingen
Development, design and manufacturing: all from a single source.
As a cable assembly specialist and systems partner we manufacture cable sets, wiring harnesses and electromechanical sub-assemblies. On request we take on the complete development of your cable system, from technical consulting and design with EPLAN through to the prototype and series production.
More about Powertune- wiring harnesses produced
- 600,000
- of cable processed
- 2,400km
- founded in Kitzingen
- 2006
- customers
- 493
Company figures provided by Powertune, as of September 2026.
- All from a single sourceDevelopment, design, samples, series production, assembly and testing under one roof, with one central contact.
- Complete developmentWe develop the cable system to your requirements, including prototyping, series support and documentation.
- EPLAN in 2D and 3DOur own CAD design office with EPLAN: cable routing in the 3D model, manufacturing drawing and bill of materials in 2D.
- Short project and delivery timesShort distances between design, procurement and production, for fast samples and delivery on time.
- Flexible from single piece to seriesPrototypes, small batches and series production from the same shop floor; changes from development are incorporated quickly.
- Modern machineryFully automatic cable processing machines with process monitoring, ultrasonic splicing and electrical final testing with a report.
From our production
Made in Kitzingen. In use worldwide.
A selection from our production: from the sensor set for agricultural machinery to the motor cable for drones.
Series production · 100 % tested
Made in Germany
01 / 08
Industry solutions
Ten industries. One standard of precision.
Every industry has its own requirements for installation space, load, interfaces and testability. We tailor every cable system precisely to them.
Automotive
Wiring harnesses for vehicle electrical systems, sensors, control units and high-voltage applications, from prototype to volume production.
Mechanical engineering & robotics
Transmitting power, signals and data reliably, for plants, machines and robots.
Special vehicles
Emergency, construction, expedition and special-purpose vehicles.
Electrical engineering & control cabinets
Pre-assembled for control cabinets and controls, delivered just in time.
Sub-assemblies
Ready-to-install system solutions from a single source.
Agricultural technology
Rugged for agricultural machinery and heavy vehicles.
Aerospace
Drones, aircraft and space technology.
Defense
Safety-critical applications.
Medical technology
Cable systems for medical devices, diagnostics and therapy.
Food technology
Watertight and resistant to cleaning for production and packaging lines.
Services
From the first sample to series production.
From a simple connecting lead to a complete vehicle electrical system, based on your drawing, bill of materials, 3D data, a sample or a specification.
Development & design
Our own CAD design office with EPLAN: we develop complete cable systems on behalf of our customers, including prototyping, series support and documentation to PPAP.
- Design from a drawing, bill of materials, 3D data or specification
- Selection of wires, connectors and protection systems
- CAD drawing, cutting lists and bills of materials
- Documentation to PPAP
Prototyping
Samples, single pieces and pilot runs: changes during the development phase are incorporated quickly. That shortens development times and speeds up market launches.
- Sample and prototype manufacturing
- Pilot runs and small batches
- Fast implementation of changes
- Seamless transition into series production
Series production
Fully automatic cable processing machines with crimp force monitoring, ultrasonic splicing and an MES that schedules orders by priority and due date: reproducible, traceable, on time.
- Automatic cutting, stripping and crimping
- Tinning, soldering and ultrasonic welding
- Batch and process traceability
- 100 % electrical final testing
Sub-assemblies
From the connecting lead to the ready to install electromechanical sub-assembly, with one contact throughout the entire product life cycle.
- Assembly of electrical and electromechanical sub-assemblies
- Integration of wiring and components
- Customised system modules
- Delivery ready for installation
Collaboration
Your cable set in five steps.
Alignment
Our sales team gets in touch promptly and clarifies all requirements directly with you.
Design
The engineering team prepares the CAD drawing, the cutting lists and the bills of materials for procurement.
Production
Once you have given your approval, production of the wiring harnesses starts at our plant in Kitzingen.
Delivery
We coordinate the logistics so that your wiring harnesses arrive on time.
Machines and process monitoring
How a cable set is made.
From the wire reel to the shipping box: this is how a cable set moves through our production, step by step, with process monitoring on the machines.
To our machinery Skip animation- Cutting
- Stripping
- Sealing
- Crimping
- Inserting
- Bundling
- Clips & labels
- Testing
- Packing
Station 01
Cutting
Length0 mm
Station 02
Stripping
Cut-in
Station 03
Crimping
CFA+
Station 04
Testing
Test
- 01 · Cutting
From the reel to length.
The wire runs from the reel through the straightener and the feed unit. Once the programmed length is reached, the blade cuts it.
Length 1,250 mm as an example
- 02 · Stripping
Insulation off, strands exposed.
The stripping blades cut into the insulation without damaging the conductor. The slug is pulled off and the copper strands are exposed.
- 03 · Sealing
Single wire seal fitted.
The seal is pushed over the strands onto the insulation. Inside the connector housing it will later seal the wire.
- 04 · Crimping
Crimped and monitored.
The crimp tool closes the contact’s wings around the strands and the seal. Crimp force monitoring (CFA+) compares the force curve of every crimp with the reference.
Force curve as an example
- 05 · Inserting
Latched and flush.
The contact is inserted into the connector housing until it latches. The single wire seal sits flush, no contact metal remains visible.
- 06 · Bundling
Cable protection to customer specification.
The wires are bundled into a harness and protected with corrugated tube, braided sleeve or fabric tape, depending on the requirements.
- 07 · Clips & labels
Fixed and labelled.
Fixing clips sit at the specified points; labels identify the connectors and the part number.
Labelling as an example
- 08 · Testing
Electrically tested.
All connectors go into test adapters and the test system checks continuity and short circuits. Only then is the harness OK.
Test pulses visualised, not a measurement
- 09 · Packing
Ready to ship.
The finished harness is coiled, placed in the box and given a shipping label.
Schematic illustration, not a customer project
Schematic illustration · example values
Quality management
Tested before it counts.
Every assembly passes defined test processes, documented and fully traceable, from a single wire to the finished harness.
- Crimp force monitoringOK
- Continuity testOK
- Short-circuit testOK
- Resistance value120 Ω · example
- Diode, forward direction0.7 V · example
- Capacitor100 nF · example
- High-voltage testas required
Schematic example. We define the scope of testing for each project.
More about quality managementDigital manufacturing
Orders you can follow.
Since 2021/2022 an MES has scheduled our production orders by priority, due date and customer requirement. Stock, batches and process steps are recorded in the system. That keeps every delivery fully traceable.
Out of this practice we develop our own software for manufacturing under the WEKAS brand. The production software project is called POM.
- Order createdDue date and priority defined
- Material readyStock reports availability
- Cable processingCutting, stripping, crimping
- AssemblyAssembly board, protection, labelling
- TestingElectrical final test with report
- DispatchDelivery with batch reference
Company
Family business. Systems partner. Since 2006.
What began in 2006 with vehicle accessories is today a development and systems partner for cable systems, grown step by step with the tasks our customers set us.
- 2006The start in Kitzingen
Norbert Warda founds Powertune: the first customer specific cable systems, connectors and adapters for vehicle accessories.
- 2009Automated processing
The first Komax fully automatic cable processing machines, plus crimping machines and semi automatic machines.
- 2011Soldering, ESD, testing
Soldering lines, ESD workstations and electrical testing with automatic logging.
- 2016New industries
Mechanical engineering, special vehicle manufacturing and electrical engineering are added.
- 2018The next generation
Philip Warda joins the family business; ERP and the digitalisation of production begin.
- 2023Our own design office
CAD design office with EPLAN: complete cable systems on behalf of our customers.
Cable assembly in Germany
Wiring harnesses and cable assemblies, made in Germany.
Powertune is a cable assembly specialist and wiring harness manufacturer in Kitzingen near Würzburg. We produce assembled cables, cable sets and wiring harnesses for customers in Germany and abroad.
What is cable assembly?
Cable assembly is the manufacture of ready to connect cables, wires and wiring harnesses to customer specification. Wires are cut to length, stripped, crimped with contacts, soldered or ultrasonically welded, labelled and built into cable sets ready for installation.
This includes electrical testing and complete documentation, so that every cable set can be fitted at the customer without rework.
Wiring harness manufacturing from prototype to series production
Whether a single piece, a pilot run or series production: we build wiring harnesses from a drawing, bill of materials, 3D data or a sample. Changes from the development phase are incorporated quickly.
In series production, fully automatic cable processing machines, crimp force monitoring and an MES ensure reproducible quality and traceability down to the individual wire.
Cable assembly specialist for industry and automotive
Our assembled cables and cable sets are at work in automotive and special vehicle manufacturing, in machinery and plant engineering, in electrical engineering and control cabinet construction, in agricultural, medical and food technology as well as in aerospace.
The range extends from sensor wires and CAN bus sets through control and data cables to battery and high voltage cables.
- Cable assembly
- Wiring harness manufacturing
- Cable sets
- Assembled cables
- Crimping
- Ultrasonic welding
- Prototyping
- Series production
- Sub-assemblies
- Kitzingen · Würzburg · Bavaria
- Made in Germany
Looking for individual components only? Connectors, crimp contacts, cavity plugs and single wire seals are available from powercable.de, the distribution site for cable assembly components.
FAQ
Frequently asked questions about cable assembly.
What is cable assembly?
The individual manufacture and assembly of ready to connect cables, wires, wiring harnesses and cable systems to customer specification, with connectors, contacts, wire end ferrules, protective and heat shrink tubing, including electrical testing and documentation.
Do you also make prototypes and small batches?
Yes. Alongside series production we make prototypes, single pieces, pilot runs and small batches. Changes can be implemented and tested quickly before series production starts.
How do you ensure the quality of assembled cables?
With incoming goods inspection, documented manufacturing processes, crimp force monitoring and dimensional checks, electrical continuity and short circuit tests, functional tests as well as visual and final inspections. On request we provide test records and measurement reports.
What documents do you need for a quote?
A drawing, bill of materials, 3D data, a sample or a specification is enough. Simply upload the files in the enquiry form. Our sales team will get in touch promptly.
What is the difference between AWG and mm²?
AWG (American Wire Gauge) is an American measure of the conductor diameter, mm² states the conductor cross section. The smaller the AWG number, the larger the cross section: AWG 20 corresponds to about 0.52 mm², AWG 18 to about 0.82 mm². To the conversion table
News
News from Kitzingen.
Careers
Join us where connections are made.
A family business, modern machinery, short distances. Apply directly by e-mail to application@powertune.de.
Apply speculatively Careers & benefits- Production Worker Cable Assembly (m/f/d)Production · Kitzingen
- Cable Processing Technician (m/f/d)Technology · Kitzingen
- Design Engineer Cable Systems & Production Planning (m/f/d)Design · Kitzingen
- Technical Project Manager Cable Systems & Electrical Engineering (m/f/d)Project management · Kitzingen
- Homeworker Cable Assembly (m/f/d)Mini job · home working
- Cleaner (m/f/d)Mini job · 3 to 6 hrs per week
Contact
Let’s talk about your project.
Drawing, bill of materials, 3D data, sample or specification: we will get back to you with a non-binding quote.
Powertune Spezialkabelsysteme GmbH & Co. KG · Johann-Adam-Kleinschroth Str. 10 · 97318 Kitzingen