What to Look for When Comparing Wire and Cable Harness Manufacturers

Cable Manufacturer

When you start looking for the perfect solution to your unique cable and wire harness needs, it can be a bit daunting trying to decide between different manufacturers. Just looking over websites might only give you a partial picture as to the capabilities of one firm over another. So what do you use to compare different cable and wire harness manufacturers? 

Today’s spotlight is focused on how to find the best manufacturer to meet the specifications your project demands. 

Past Experience in Custom Wire and Cable Harness Manufacturing

There are many off-the-shelf cable and wire harnesses out there but rarely do these products check all of the boxes the end-user needs to ensure safe and reliable function. Simply put, manufacturers with limited experience in custom cable and wire harnesses will lack the expertise needed to adapt during the manufacturing process. 

With decades of experience under our belts as a custom cable and wire harness manufacturer, Meridian is uniquely poised to meet the tough demands of some of the most demanding projects on Planet Earth, and beyond. 

First up, always look at a manufacturer’s track record for producing products of the same nature as your custom build. We are proud to have produced the harnesses necessary to provide critical infrastructure in industries such as the military, medical, industrial, and telecommunications. 

  • Military – the military subjects cable and wire harness components to some of the harshest environments on the planet. Building to MILSPEC takes many years of experience and some truly gifted designers, as these products need to be extremely tough. With military men and women counting on the electronic systems our harnesses help make possible, our commitment to integrity, functionality, and safety is paramount.
  • Medical – the medical field uses incredibly advanced equipment to save lives, diagnose, and treat patients every day. Some of these electronics require sensitive considerations like a biomedical jack or specialized strain reliefs. Knowing our cable and wire harnesses must perform exactly as required within medical devices and equipment is all the more highlighted when someone’s health and wellbeing are on the line.
  • Industrial industrial control systems help to power the automation behind massive processing and manufacturing facilities. As well, these systems help control utilities and other necessary municipal functions like water treatment facilities. Cable and wire harnesses play an integral role in providing the infrastructure needed to transmit power, data, and signals throughout the system.
  • Telecommunications – today’s world has never been more connected, nor have we ever relied so heavily on communications infrastructure to keep the data flowing. With a heavy emphasis on beefing up the world’s telecommunications capabilities in the last few decades, Meridian has been at the forefront by providing the specific harnesses needed in highly-sophisticated and sensitive communications equipment.

While these four industries represent the core of Meridian’s prowess as a cable and wire harness manufacturer, we have also built up an incredible level of expertise in a vast number of other industries, as well. The best manufacturer is one that is familiar with your industry and can anticipate the needs of the project, even before the client may have fully articulated them. 

From the very first concept meeting right through volume production, our gifted designers and engineers have the experience necessary to produce a product that we know will work as intended, under whatever circumstance our client needs them to. This is where having an experienced custom manufacturer pays huge dividends and can save a project both time and money.

Capabilities of the Custom Wiring Harness Manufacturer

Next, as you compare different harness manufacturers, make sure to pay close attention to the capabilities they have. This may seem basic, but in manufacturing there are many companies that offer a very limited scope of capabilities and may be sourcing the majority of components from other manufacturers. 

Meridian is proud to custom create over 70% of the products that come off our assembly line. In addition to a wealth of experience, this has enabled us to build an incredible tooling inventory from which to choose from to complete the task exactly as required. In fact, we have amassed over 5,000 existing tools, connectors, and other components to be available to complete the project. During the design phase, we also employ some of the most sophisticated design software available today to produce a digital blueprint to follow all the way to volume manufacturing. With such a massive “library” of tools and equipment at our disposal, we have some of the highest levels of capability in the industry. 

Having a blend of hand tools, semi-automated, and fully-automated equipment provides a great level of product breadth and depth when it comes to manufacturing harnesses. We are able to produce a wide range of different harnesses and can also produce many different iterations of one particular type. We have found this combination of experience and capability to be crucial to our success as a custom wiring harness manufacturer.

Commitment to Quality

Quality can be overlooked as you compare different manufacturers as everyone says they are committed to it. If everyone is doing it, what does it really matter? Actually, a great deal as one’s definition of what quality is and what requirements it places on every step of the manufacturing process can vary. 

We’ve mentioned that our cable and wire harnesses are used in some pretty exacting industries, where a mistake can mean much more than time, money, or our reputation. With so much at stake, we take quality to extreme levels. 

With Quality Assurance and Quality Assurance (QAQC) engineers whose sole mission is to ensure functionality, integrity, and safety of the product and the process, quality becomes very much data-driven. Testing is a crucial step that is implemented throughout the design and manufacturing process in order to ensure quality. It is indeed quite rare for a product to go from concept to volume manufacturing without a prototyping phase. We are proud to be able to say we test each and every product multiple times throughout the process but especially once complete and before the product ships to our customers worldwide. We want our clients to be absolutely sure the product they receive functions reliably cycle-after-cycle.

Prototyping allows our engineers a chance to test how different variations come together and function together as part of the larger system. We are also able to measure how well we can source the necessary materials to complete the project both on-time and on-budget. Manufacturers that skip prototyping will generally be costing more in the long run as the product undergoes real-world conditions and may even lead to premature failure. 

We even created a means to test our products under real-world conditions in our Advanced Life Testing Lab. Factors like salt spray, water, humidity, heat, friction, and bending all need to be considered and mitigated against within a cable harness’s engineering. The Advanced Life Testing Lab gives our engineers a chance to review how components hold up under the actual conditions they’re likely to face. This also gives a chance to tweak anything that doesn’t meet the exacting standards set forth in the project plan.

What Industry Certifications Matter Most 

Continuing with our discussion of quality is the certifications that a manufacturer possesses. You may not necessarily group a certification with quality; however, Meridian is proud to be certified exactly for our commitment to quality. 

ISO 9001 is an internationally recognized certification that has incredibly high standards. We are very proud to have and maintain our certification in this rigorous quality assurance standard. ISO 9001 requires a continued commitment not just to quality of the product and the process, but also in customer service. By continuing to focus on making our processes better, we have continually sought to eliminate process waste and fix any issues before they impact a project. 

Another truly crucial certification to look for in your cable harness manufacturer is that of a UL-approved manufacturing facility. The little stamp with the “UL” inside a circle on the bottom of most every electronic product you purchase means that product has met the stringent requirements as set forth by UL, or Underwriters Laboratory. UL is one of only a very small handful of government-approved independent standards creators. As a UL-approved facility, we are able to produce products that meet UL’s strict requirements and can help get our client’s products UL-certified, as well when it’s desired.

Starting Your Custom Wire or Cable Harness Project

Starting your project can seem daunting when you first start comparing cable and wiring harness manufacturers. However, by going with a manufacturer with the unique experience, capabilities, commitment to quality, and certifications necessary to produce custom solutions, you can be sure your harness is perfectly suited to meet the demands required of it. At Meridian, we are proud to have built a reputation as a manufacturer that can deliver, no matter what specifications are required. Contact our team today to start reviewing your project’s unique specs and see what sets our process and products apart.