Assembling Wiring Harnesses with 100% Electrical Testing

The base price is determined primarily by the number of wires and contacts and the associated production time. All components, wire lengths, connector systems, and protection via corrugated tubing or braiding are clearly itemized. Added to this are labeling and the scope of testing. The quantity ordered has the greatest impact on the price. A large portion of the work on the wiring harness is done by hand, so the unit price decreases with larger batch sizes, as setup costs and setup time are reduced. For large production runs, we offer manufacturing in Portugal. We provide a firm price for cable harness assembly in our quote based on your drawing. In purchasing documents, this scope of work is often referred to as “cable set manufacturing.”

Wiring harnesses are largely manufactured by hand. Wherever possible, the individual steps are carried out with machine assistance to maximize reproducibility and quality. Wires are cut to length and stripped, contacts are crimped, and the wires are inserted into connector housings. The wires are then routed and bundled, and finally protected. The process concludes with labeling and electrical testing. At rokatec, cable harness manufacturing includes process checks such as crimp height and pull-out force, as well as a final electrical test of each individual cable harness.

The wires are cut to length and stripped. They are then fitted with crimp connectors. Depending on the requirements, soldering or ultrasonic welding may also be performed. The connectors are then inserted into the housings, and the wires are routed and bundled. To protect them from aging and environmental influences, they are enclosed in corrugated tubing, braided tubing, or wrapped with high-quality fabric tape. The cable harness manufacturing process concludes with labeling and electrical testing.

To request a quote, all we need is a wiring harness drawing that includes wire lengths and cross-sections, connectors, connector housings, and a bill of materials (BOM). Please also provide the planned quantity. If no drawing is available, a schematic diagram or an existing sample will suffice; we will then create the drawing as part of the cable harness development process. Information about the operating environment helps us select the appropriate wires, connectors, and components.

Every wiring harness at rokatec undergoes a final electrical test for continuity and insulation, as well as an optional high-voltage test. During production, we inspect crimp connections through visual inspection and crimp depth measurement. We also measure pull-out force and examine cross-sectional micrographs. All testing processes and results are documented and recorded digitally. The test report is available upon request. We operate in accordance with IPC/WHMA-A-620 or, upon agreement, in accordance with the customer’s in-house standards. Learn more about our quality assurance.

Wiring harnesses are produced by manufacturers, who are also referred to as wiring harness assemblers. Large corporations supply the automotive industry with high-volume production, while medium-sized manufacturers produce custom cable harnesses for mechanical engineering or agricultural machinery. Rokatec belongs to the second group: Production takes place in Emlichheim, Lower Saxony, near the Dutch border. As a cable assembly manufacturer, we produce small and medium-sized production runs in Germany. Large-scale production takes place at our own plant in Portugal. Each year, we produce over 1,000 different types of cable harnesses, ranging from prototypes to large-scale production runs.

In Germany, in addition to the major automotive suppliers, there are many medium-sized wiring harness manufacturers, each with its own area of specialization. Some focus primarily on high-volume production, while others specialize in medical technology, rail, or mechanical engineering. Rokatec, based in Emlichheim, specializes in custom cable harnesses for agricultural and construction machinery, specialty vehicles, and industrial applications, with 50 years of experience and manufacturing in accordance with IPC/WHMA-A-620. If you’re looking for a cable harness manufacturer for small-batch production, you’ve come to the right place.

A custom wiring harness is built for exactly one application. Cable lengths and branch connections are tailored to the installation configuration in a specific machine, as are connectors and protective features. Such a wiring harness therefore will not fit into a second application. The basis for production is a drawing, a schematic diagram, or a sample provided by the manufacturer. Rokatec manufactures exclusively custom-made wiring harnesses, ranging from individual prototypes to series production.

In practice, both terms mean the same thing: multiple wires bundled together to distribute power and signals within a machine or vehicle. “Wiring harness” emphasizes the bundled set of wires, while “cable harness” refers to the branched configuration with branches leading to individual loads. There is no difference in construction or testing. Rokatec manufactures both according to the same drawings and testing procedures.

No. Rokatec manufactures everything from individual prototypes to high-volume production. The batch size that makes the most economic sense for you depends on the quantity, the harness design, and its connector systems. With over 1,000 different types of wiring harnesses produced each year, frequent variant changes are part of our daily routine. If your production volumes increase, we can offer competitive prices for wiring harness manufacturing in Eastern Europe through our facility in Portugal.

Yes. Even if we only have a schematic, specifications, or an old prototype, we’ll use them to develop the manufacturing drawing, including cable routing, lengths, connectors, and protection. Creating a BOM (bill of materials) for the wiring harness is also standard for us. In doing so, we advise on the selection of oil- and chemical-resistant cables and on the placement of solder points. We incorporate any components you specify as the manufacturer into the drawing. The development service is optional and can also be commissioned as a standalone service, independent of subsequent cable harness production.