Case background
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Industry background
Competition is extremely fierce in these industries. In the past two years, the Australian construction industry has faced the problem of a wave of closures. Although Australia has taken measures to increase housing supply, it has encountered significant obstacles. The most important problem is the continuous increase in the wiring harness cost in the construction industry.
Globally, the Waterloo phenomenon of chemical industry giants reflects the industry's predicament and performance pressure. In the second quarter of 2025, the capacity utilization rate of the German chemical industry was only 72%, hitting the lowest level in over 30 years. To survive and develop in a highly competitive industry, enterprises are confronted with the problem of ensuring product quality while controlling Wiring Harness Cost.
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User requirements
If you want to replace the factory wiring harness and find a stable wiring harness supplier for the product, you are facing problems such as cost of wiring harness pressure, long delivery cycle and unstable supply chain.
Solution
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Customized process
01
Demand Analysis
Our team will communicate with the customer's engineers to understand the design and structure of the product, the customer's performance requirements for the product, various product parameters and other information, providing data for our subsequent improvement and optimization of the product's wiring harness structure. And understand the customer's requirements for the custom wiring harness cost of the product. Within the range that meets these conditions, we began to customize the wiring harness solution for the customer.
02
Material Procurement and Optimization
We have cooperated with many well-known wire harness manufacturers around the world, such as Tyco, Amphenol, Molex, etc. With over 10 years of procurement experience, we have developed a standardized procurement system that enables us to quickly find suitable materials for our customers.
At the same time, there are also Chinese manufacturers to choose from. We will combine all the data for comparison, select the material with the most cost-effective price among the same product performance, and make the most optimized material purchase through wire hamess costing calculation.Minimize the wiring harness cost.
03
Flexible production
We can carry out customized production based on the parameters such as the length, spacing and size of the parts required by the customers. The aim is to reduce the wiring harness cost, simplify the production process to increase the production speed, and eliminate the waste of materials to reduce resource consumption.
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Technical capability
ECOCABLES has built a product R&D and design team with over 10 years of experience. Based on their research on wire harness products, they can quickly respond to various market demands. Our R&D and design team can help users clarify product concepts, optimize design drawings, provide selection strategies for product raw materials, minimize the wiring harness cost as much as possible, and develop new products Finally, it includes all the projects for delivering the product to the user.
Among all the effects of reducing the wiring harness cost, the cost reduction in R&D and design accounts for more than 80%. Only the cost reduction in product design can truly lower the wiring harness cost. Our product R&D and design team will focus on four aspects to create "cost reduction design" : parts, assembly, design, and innovation.
Parts
In terms of cost reduction for parts, cost reduction is carried out on the smallest units that make up the product. Multiple parts make up a product, and parts can be processed and manufactured through various techniques.
Assembly
In terms of assembly cost reduction, multiple components are assembled into a product. The assembly is redesigned to shorten the time of the assembly process and improve assembly efficiency at the same time.
Design
In terms of cost reduction in design, a product is composed of multiple components. By simplifying the structural design of the product, the number of parts used in the product is reduced.
Innovation
In terms of cost reduction through innovation, it refers to the selection of new materials, new assembly processes and new manufacturing processes for products.
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Factory manufacturing and processing
Our factory is located in Dongguan, China, which is known as the "World Factory". We have a research and development team with 20 years of rich experience, which helps users accurately identify their needs, design perfect drawings, configure materials specified by users and provide strategies to reduce the wiring harness cost. This includes the design and manufacture of wiring harnesses, connectors, molds, etc.
All raw materials comply with the ROHS standard and have passed strict SGS testing and factory ISO certification. All products meet international quality standards.
The core of reducing the wiring harness cost in product design can be summarized into three aspects:
1.DFM. Design oriented towards production and manufacturing reduces the production cost of products.
In terms of assembly design, increase the speed of product assembly and packaging. In terms of cost design, choose components with high cost performance.In terms of manufacturing, enhance the manufacturing efficiency of non-standard components.
2.VAVE. Value analysis and value engineering, reducing the cost of useless materials.
Reduce the quantity and either reduce or merge materials that do not affect functionality. Reduce weight. In performance reliability tests, screen out the weight of materials that will not affect performance. Reduce functions. Based on the analysis of functional value, screen out functions that are both of low value and high cost.
3.TRIZ. Innovative design reduces costs.
For example: Material simplification, part design from multiple to one. Technological innovation has transformed the material processing technology from CNC to stamping forming. Modular design modularizes highly reusable functions.
In our customization team, the core for reducing the wiring harness cost:
By leveraging the advantages of our product R&D and design team, we create solutions that meet users' needs and budgets. Our procurement team purchases the most cost-effective materials globally based on a standardized procurement system. During the precise manufacturing and processing by the factory's manufacturing team, the products are formed and then subject to practical application tests.
Specific case presentation
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Customer pain points
In the left picture, it is a group photo of our team manager and the client.This customer is a pump manufacturer from Australia. They sent us the wiring harness diagrams and samples of their products, hoping that we could create a solution suitable for their products to reduce product wiring harness cost.
one-stop solution
professional team
high quality
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Wiring harness cost design solutions
In the following picture, it can be clearly seen that there are differences between the wiring harness parts before and after optimization. Under the premise of not affecting the function and quality of the parts, we have optimized them into the same but more cost-effective parts. The main reason is that we used the Amphenol brand to replace the TE brand, the TE brand to replace the IFM brand, and our local heat shrink tubing method to replace the customer's tubing method, which saved the customer a lot of Wiring harness cost.
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Wiring harness cost Optimization result
From the comparison of the pictures before and after the optimization mentioned above, we can directly see that some parts have similar structures, some parts that do not affect the functional use have been simplified, and material costs have been saved. There are also parts with the same function. We will choose the same but cheaper parts to replace them.
This is a highly successful customized case of reducing the wiring harness cost, directly saving the customer 100USD/PCS in wiring harness costs.
Summary
Through the customer cases we have served, you can clearly see our professionalism in customizing wire harnesses and our ability to reduce the wiring harness cost. With the tailor-made solutions we provide for you, you will find all the products you need.
In custom made wiring harness service. You can send us the wiring harness diagrams and samples, and we will design a solution that suits you. The project content includes material selection, structural design, control of the wiring harness cost, practical application testing, etc. You can specify the material manufacturer, and we can also find substitutes for you to save costs while ensuring the practical application of the product. We always support you via email (sales003@ecocables.cn) and phone (mobile: +8613412331588).
We produce wire harness products suitable for various scenarios, including:
Frequently Asked Questions
Q: How to reduce wiring harness installation costs?
A: 1. Simplify the design.Integrate the wiring harness path, eliminate some redundant functional integrations, merge branches or interfaces, and wiring harnesses.The degree of integration has been enhanced, and the wiring harness cost has been saved, such as the extra interfaces and the binding materials and outer covers required for jacket.
2. Generalized design. The widespread development and use of universal parts can achieve the reuse of common resources, reduce the wiring harness cost, such as R&D expenses and production costs, and shorten the R&D cycle, allowing the most economical part combination method to complete the assembly of wire harnesses.
3. Bulk purchasing. For large-scale wire harness manufacturers, many electronic components of wire harnesses have been standardized. Enterprises can purchase from material suppliers together with other enterprises in the group. The larger the order quantity, the more advantages they have when bargaining. At the same time, it can also avoid the price differences of wire harnesses when each enterprise purchases separately.
4. Supplier database establishment and management. A directory of qualified and high-quality suppliers for wire harness products can be established. Under the condition of not affecting the quality and production cycle of the wire harness products, wire harness materials with high cost performance can be compared and screened, thereby reducing the wiring harness cost.
Q: Why is a wiring harness price so expensive?
A: 1. The cost of raw materials accounts for a relatively high proportion. The price of copper raw materials accounts for 30% to 50% of the wiring harness cost. Especially with the continuous growth of the industry's demand for high-purity copper wires, it has led to a situation where the price of high materials is pushed up.
2. The process complexity is relatively high. The launch of an automated wiring production line requires an investment of up to tens of millions of yuan in equipment, which has driven up production costs.
3. It has quality and brand effects. High-quality wire harness raw materials use electrolytic copper and high-quality insulating materials, which enhance durability. However, the cost also increases accordingly. As a result, the overall harness wire price will rise. For some enterprises, due to brand licensing issues, the cost usually becomes even higher.