The starting question: make or buy?
Many manufacturers assemble their cables themselves at first: a few cables for the prototype, a handful of cable sets for the first small series. Once demand grows, the question arises whether in-house production pays off in the long run or whether a cable assembly supplier can do it better and at a lower price.
To answer that, it is worth looking at the total cost. Besides material and working time, this includes tools, machines, test equipment, qualification, scrap and the effort involved in providing evidence.
The case for outsourcing
- Know-how: which contact fits which cross section, which crimp height applies and how a wiring harness is built so that it can be tested is a matter of experience.
- Purchasing: a cable assembly supplier buys cables, contacts and connectors in larger quantities and for many customers. That lowers prices and shortens procurement times.
- Machinery: fully automatic cable processing machines, semi-automatic machines, crimping tools for every contact system, ultrasonic welding and test systems cost a lot of money. They only pay off at high utilisation.
- Synergies: because the machines run for many orders, setup and acquisition costs are spread across large quantities.
- Process reliability: monitored crimps, electrical testing of every wiring harness and complete traceability are standard at a specialist.
- Capacity freed up: your team concentrates on the development and assembly of your own product.
When in-house production can still make sense
Simple single cables in small quantities that are adapted directly on the assembly line can often be produced well in your own plant. Individual repairs or adjustments in the field do not need a supplier either.
As soon as crimp contacts in series production, sealed connectors, evidence for your customers or a large number of variants come into play, the calculation usually tips in favour of the specialist.
How to recognise a good cable assembly supplier
- Monitored processes: crimp force monitoring and measured crimp height
- Electrical testing of every wiring harness, test records on request
- Quality management, for example to ISO 9001, and complete traceability
- Its own design office for drawing, bill of materials and changes
- Sample, small series and series production from a single source
- Openness: a plant tour and a supplier audit are possible
Cable assembly at Powertune
Since 2006 we have been manufacturing cable sets and wiring harnesses in Kitzingen for 493 customers (as of September 2026). Our machinery ranges from the Komax Gamma 450 fully automatic cable processing machine to the ultrasonic welding machine, and every wiring harness is tested electrically. We process cross sections from 0.013 to 70 mm², and up to 95 mm² where required.
Material that you source yourself can be supplied to us, and for assemblies also the devices into which we install the wiring harnesses. For recurring demand there are framework agreements with call-offs or Kanban racks. You will usually receive a quote within 2 to 3 working days.
The page How a project works shows the steps of a project with us. The enquiry checklist sums up what belongs in your enquiry.
