Your material
Supply material yourself
Cables, connectors or special components that you source yourself are processed by us as well. With assemblies this also covers the devices into which we install the wiring harnesses.
Module assembly- Home
- Project process
Project process
How a project works.
From the first enquiry to tested series production: in six steps, with fixed contacts and short distances between design, production and testing.
Overview
Six steps to your wiring harness.
Not every project needs every step: if a finished drawing is available, the design work is omitted; for a rebuild we start with the sample.
- Enquiry
You send us whatever you have: a drawing, a bill of materials, 3D data, a sample or a description.
More - Clarification and quote
We clarify the open points and usually send you a quote within 2 to 3 working days.
More - Design
On request our design office develops the wiring harness with EPLAN, through to the assembly board drawing.
More - Sample and approval
Samples are made with the same processes and tests as series production. Changes are fed in directly.
More - Series production
The MES schedules your orders, the machines monitor every crimp, every wiring harness is tested electrically.
More - Delivery and support
Marked, packed and delivered worldwide, traceable down to the individual cable.
More
Step 1 · Enquiry
Send us whatever you have.
For a reliable quote, a drawing, a bill of materials, 3D data, a sample or a specification is enough. Quantities and call-off volumes, your preferred date and any special requirements for the environment, sealing or testing are helpful as well.
No drawing available? Then sketch the wiring harness in the enquiry form or send us photos. What belongs in a good enquiry is summarised in the enquiry checklist, also available as a fillable PDF.
Step 2 · Clarification and quote
Clarify first, then calculate.
Our sales team gets in touch promptly and discusses the details with you: by telephone, in a Teams meeting or by e-mail. If details are missing, on the connectors or on the scope of testing for example, we clarify them with you instead of building the quote on assumptions.
You will usually receive the quote within 2 to 3 working days. Exactly how quickly depends on the material: we often have standard components in stock, and for exotic special parts we wait for the quotes from our suppliers.
Step 3 · Design
From the 3D model to the assembly board drawing.
If your project needs design work, our CAD design office develops the wiring harness with EPLAN Harness proD: cable routing in the 3D model, an assembly board drawing at a scale of 1:1, a bill of materials and a cutting list. You receive the documents for approval.
You can read more under Development & design and in the article From the 3D model to the assembly board.
Step 4 · Sample and approval
The sample shows whether everything fits.
We make samples and prototypes with the same processes and tests as the later series production. Changes from the first installation are fed into the drawing and into production, and every change status is documented.
Series production starts after your approval, on request with an initial sample inspection or documentation to PPAP.
Step 5 · Series production
Scheduled, monitored, tested.
Our MES schedules the orders by priority and due date. Fully automatic cable processing machines monitor every crimp and eject faulty cables; assembly takes place on the assembly board. Every wiring harness goes through electrical final testing, on two test systems from Engberts (iCAT) or on test boards.
For recurring demand we agree framework contracts with call-offs, or we supply your assembly from Kanban racks. We implement changes flexibly and seamlessly in series production, up to shortly before your order.
Step 6 · Delivery and support
Marked and delivered, worldwide.
We mark to your specification (with labels, by inkjet printing on the cables or packed in resealable bags) and deliver worldwide, currently to the USA, the United Kingdom, Switzerland, Austria, Slovenia and Spain among others. Test records are available with every delivery on request.
Every delivery is traceable down to the individual cable. If something is not right after all, we handle the complaint in a structured way with an 8D report.
Working together
What else you should know.
Cross sections
0.013 to 70 mm²
From the finest strands to battery and power cables, up to 95 mm² where required, including for high voltage cable sets.
MachineryOpenness
Visit the plant
Factory visits and supplier audits are possible by arrangement. We will send you our ISO 9001 certificate on request.
Quality managementHow quickly do I receive a quote?
Usually within 2 to 3 working days. Exactly how quickly depends on the material: we often have standard components in stock, and for exotic special parts we wait for the quotes from our suppliers.
Do I have to order every step from Powertune?
No. You can order the development only, the production only or both. If a finished drawing is available, we start straight away with the quote and the sample.
Can we still bring in changes?
Yes. We implement changes flexibly and seamlessly in series production, up to shortly before your order. Every change status is documented.
Can we visit your production beforehand?
Yes. Factory visits and supplier audits are possible by arrangement: by telephone on +49 9321 3924811 or by e-mail to info@powertune.de.
Step 1
Let us start with your enquiry.
Send us a drawing, a bill of materials or a sample, or sketch your wiring harness directly in the enquiry form.