Analyzing the Costs to Hire a Wire Harness Engineer

meeting with wire harness engineers

Wire harness engineers may seem like an expensive aspect of a wire harness fabrication project and you may be thinking, is an engineer really necessary for my wire harness build out? However, these professionals have the training, experience, and often the advanced certification required to be able to produce a wiring harness that ensures absolute continuity for the system they support. In today’s spotlight, we’ll run a complete analysis of all the costs involved and look at the value of having a wire harness engineer on your business’s next custom wire harness project.

How Much Does a Wire Harness Engineer Cost?

A wire harness engineer is typically a specialized set of electrical or mechanical engineers. These pros typically have a Bachelor’s degree in Electrical or Mechanical Engineering and then several years of experience under their belt before they ever sit for licensing. Once licensed, the engineer can sign and seal a set of plans for accuracy and safety.  While they are typically electrical or mechanical engineers, that can be from other engineering fields as well.

Wire harness engineers on average cost between $55 and $155 per hour depending on factors like the complexity, size of the project and their employer’s overhead. Wire harness engineers are gifted in the design, testing, and production processes required to produce a perfect solution to the client’s toughest issues. While the costs to have a wire harness engineer on your project may seem expensive, we’ll show you just how much time and money a wire harness engineer saves during custom wire harness fabrication over the course of the project. 

Benefits of Having a Wire Harness Engineer on a Custom Project

Wire harness engineers are a lot like football coaches that envision the perfect play for their team, detail everyone’s responsibility to pull it off, practice, and finally pull off the play perfectly. When you first start custom wire harness fabrication, the harness is carefully laid out on a specialized panel which allows pegs to be used to position each wire branch perfectly. The avenues of wires go off in varying directions, each with its own mission to complete. 

The wire harness engineer examines all of the terminations, connections, and other infrastructure needed to pull off the connectivity for powering the system or transmitting the signal. Using the layout grid allows the engineers to calculate dimensions perfectly to suit their intended application. When these dimensions are specified by the client, the engineer knows the input variables needed for their design parameters. This key information will help the wire harness engineer build out complex three-dimensional computer-aided design (CAD) models of the wiring harness before the first wire is ever extruded. 

When you have an incredibly detailed wire harness fabrication design plan in place, every step of the production process goes more smoothly. Project specifications need to be precise so that our gifted production team has the right information needed to minimize any issues and delays. 

When our production engineers receive detailed project specifications set by our experienced wire harness engineers, they’ll typically receive time and money-saving details like:

  • Spec sheets with close-up details of the connectors that show exact locations for pins.
  • A full list of wires that the project will use including the specific wire colors.
  • A full list of all the materials needed with specific part numbers.
  • A precise drawing of the final assembly with locations for labels, project tolerances, and detailed assembly instructions.
  • Specifications for testing the finished wire harness.

Remember that delays are incredibly detrimental to the project budget and timeline. When our design team puts together a project schedule, the timeline is based on accomplishing specific tasks at precise times in order to stay on schedule. So many moving parts require keen operations management principles. The project schedule uses principles first presented by Henry Gantt in the early 1900’s. Gantt’s charts would prove to be the basis for efficient project scheduling by showing how activities in a project are interdependent on one another. Wire harness engineers use other advanced methods like the critical path method (CPM) to determine the most efficient means to produce a custom wire harness. 

This level of sophistication in the design process helps to ensure projects are completed on-time and on-budget. A commitment to quality of the product and process is a driving factor behind Meridian’s continued certification in ISO 9001:2015. This rigorous certification requires a wiring harness engineer to be continually seeking new and better methods for production efficiencies, product quality, and even customer service. We have found the level of commitment required to maintain advanced industry certifications like ISO 9001 is what truly sets our custom wire harness fabrication design process apart.

A Closer Look at Engineering Fees & Other Costs

Unlike some wire harness manufacturers out there, Meridian does not typically charge for Non-recurring engineering (NRE) cost. So what are NRE costs? Typically, NRE costs will be a one-time cost for research and development (R&D) in order to design and test a brand new product for viability. At Meridian, we don’t charge a separate fee for something that should be inherent to a quality wire harness fabrication from the get-go. 

Starting Your Custom Wire Harness Project with a Knowledgeable Guide

Once the detailed project documentation is created and passed on to the design team to carry out, each process will follow a few familiar steps as it heads into production. Steps a meticulous custom wire harness fabrication process should follow include:

Review the Design. Rinse. Repeat. Okay so we’re not shampooing the wire harness but there absolutely needs to be a comprehensive review of the design in order to ensure integrity, safety, and functionality. When a client receives their custom design, the wire harness has to work as designed. Period. Our clients include those in telecommunications, medical and health technology, the military, automotive, and so many other vital industries that there simply isn’t room for error. That’s why the design review stage is so critical to overall project success. The process, parts, tools needed, and even personnel requirements will all be recalculated to ensure everything is correct and ready to be implemented.

Preparing the Materials. Logistics plays a really crucial role in the overall success of the project as sourcing materials needs to be as exact as the design itself. By using just-in-time (JIT) ordering techniques to minimize delays, our wire harness engineers are able to get quality components, right when they’re needed. We typically only use UL-certified wires and cables or are able to produce our own as a UL-approved manufacturing facility. 

Documenting the Assembly Process. While the materials are being sourced, your wiring harness engineers will be hard at work making sure the assembly documentation needed for manufacturing is complete and accurate. Meticulous assembly step-by-step instructions, complete with detailed images, illustrations, CAD drawings, and the final testing procedure will all be laid out. The physical assembly panel will also be readied and the pegs inserted in their required positions, as specified by the wire harness engineer’s design.  

Producing a One-of-a-Kind Wiring Harness. It is actually quite rare for a wire harness to go from design to volume manufacturing without first going through a prototyping stage. This allows our team the chance to review processes like the materials sourcing plan we outlined above and to test how different processes work in concert. By having a few different versions that each arrive at the same conclusion, our team is able to choose the most cost-effective and efficient means to produce the best iteration of the project. Our skilled production team will work to cut the right length of wires and lay the framework on the completed assembly panel, as specified in the design. This is when all of the connectors, terminations, wire bundling, and labeling is completed. With over 5,000 existing tools, connections, and terminations at our disposal, our gifted designers can put together the perfect amalgamation, perfectly suited for the requirements of the project.

Quality Assurance & Quality Control (QAQC). As we went through above, testing is a piece of the production process that arguably gets the most action. We test the final product to make sure it is absolutely in line with the specifications put forth by the client and detailed by the engineer’s design. We’ll make sure the wiring harness is performing as it’s required to, given the environmental factors it will face in situ. 

Given that each of these steps has a thousand tiny steps in between, orchestrating such a detailed operation takes a lot of knowledge, skill, and experience. The wire harness engineers of Meridian are some of the very best in their field because of the incredible diversity of projects we’ve been able to undertake. From highly complex industrial control systems to sophisticated aircraft controls, our team has the capability to design and produce the perfect wire harness to maintain system continuity.

Talking Over a Custom Wire Harness Design with a Wire Harness Engineer

When you’re ready for the precision and professionalism needed to complete your wire harness design on-time, on-budget, and to your exact specifications, a professional wire harness engineer is indispensable. Our streamlined process ensures your project is completed in a safe but efficient manner. Schedule a meeting with our team now to go over all of your project’s needs and to get the process started.