Series production of cable sets and wiring harnesses
Reproducible. Traceable. On schedule.
- automated order scheduling
- MES
- crimp force monitoring
- CFA+
- down to the individual cable
- Traceable
Overview
Reproducible. Traceable. On schedule.
Our machinery processes a wide range of cable types: fully automatic cable processing machines with crimp force monitoring, seal position control and cut-in monitoring, ultrasonic splicing machines and the new Schleuniger B340.
An MES schedules production orders automatically by priority, due date and customer requirement, with complete batch and process traceability from the individual cable to the finished wiring harness.
Scope of services
Series production at Powertune: what is included.
- Fully automatic cable processing machines for cutting to length, stripping and crimping
- Ultrasonic splicing
- Single wire seals and seal position control
- Automated electrical testing
- Intelligent warehouse system
- Framework and call-off orders
Every product can be documented without gaps, from the individual cable to the finished wiring harness.
Examples
From our production.
Fully automatic machines
The thousandth cable like the first.
In series production, repeatability is what counts. On fully automatic cable processing machines such as the Komax Gamma 450, cables are cut to length, stripped, fitted with single wire seals and crimped at both ends in a single pass. The machine monitors the force curve of every crimp, the position of the seal and the stripping result.
Sheathed and multicore cables are processed on the Komax Kappa 340 R with its rotary and slitting unit. Ultrasonic splices are made on the Schunk Minic III, twisted cables on the Komax BT 188 T.
Scheduling
MES scheduled and on time.
Since 2021/2022 an MES has scheduled our production orders by priority, due date and customer requirement. An ERP system and an intelligent warehouse system make sure that material and capacity match.
For recurring demand we agree framework and call-off orders. That way you plan your assembly with fixed call-off volumes, and we produce at the matching rate.
Traceability
From the individual cable to the finished wiring harness.
Complete batch and process traceability has been in place at Powertune since 2019: every product can be documented without gaps, from the individual cable to the finished wiring harness. In the event of a complaint, this makes it quick to narrow down which deliveries are affected.
You can read about the tests and records involved under testing & documentation.
FAQ
Frequently asked questions.
Which quantities do you produce in series?
From small series up to large series with framework and call-off orders. Since 2006 Powertune has manufactured 600,000 wiring harnesses and processed 2,400 km of cable (company figures, as of September 2026).
How do you ensure consistent quality in series production?
Through monitored processes and a complete final test: the fully automatic machine monitors crimp force, seal position and stripping, every wiring harness is tested electrically, and all steps are documented. Powertune is certified to ISO 9001.
Is every cable traceable?
Yes. Complete batch and process traceability has been in place since 2019, from the individual cable to the finished wiring harness.
Do you offer framework and call-off orders?
Yes. For recurring demand we agree framework agreements with call-offs; on request we supply your assembly from Kanban racks. The MES schedules production by due date and priority.
What happens if changes come up during a running series?
We implement them flexibly and seamlessly in the running series. You can introduce changes until shortly before your order. They are documented in the drawing, the bill of materials and the work instruction; every revision level remains traceable, and the scope of testing is adjusted where needed.
Request a quote
Let us talk about your project.
Send us a drawing, a bill of materials or a sample, or sketch your wiring harness directly in the enquiry form. We will get back to you with a non-binding quote.
More services
Everything from a single source.
Cable assemblyReady to install cables, cable sets and wiring harnesses
Wiring harness manufacturingWiring harnesses to drawing, sample or 3D data
Development & designCAD design with EPLAN, documentation to PPAP
PrototypingSamples, single pieces and pre-series
Testing & documentationProcess monitoring, electrical final testing, test recordsIndustry solutionsTo the overview