iconPreview: Wire Harness Assembly
iconPreview: Wire Harness Assembly

Wire harness and cable assembly

Incorrect wiring, connectivity issues, or interrupted lines are hidden defects that can bring your project to a standstill.

With the right partner for wire harness and cable assembly, you minimize these risks and build the foundation for a successful product. We back up this commitment with the highest international certifications.

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Precision in cable assembly, quality in every wire harness

As experienced EMS partner, Variosystems supports your project from development through to series production and manufactures cable systems precisely tailored to your technical requirements. From cable assembly and mounting to comprehensive electrical and visual inspections, we ensure consistently reliable connectivity and sustain high quality.

Our manufacturing and quality processes are based on internationally recognized standards:

  • ISO 9001
  • ISO 13485
  • ISO 14001
  • ISO 45001
  • UL-certified products
  • Manufacturing according to IPC-WHMA-A-620C

 

More than 450 employees manufacture scalable cable systems at our site in Sri Lanka across 6,500 m² of production space—flexibly designed for a wide range of requirements and batch sizes.

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Our expertise in wire harness assembly

Planning and design of wire harnesses

With our expert consulting, we keep your projects on track from the very beginning. Together with you, we clarify technical requirements, operating conditions, and quality specifications before wire harness production begins. This helps avoid risks such as wiring errors, unsuitable materials, or later design changes at an early stage.

 

Our goal is to reduce downtime, avoid costly troubleshooting, and establish a solid foundation for stable series production. Based on your requirements, we create detailed drawings, bills of materials, and a tailored testing strategy. This results in a technically sound, cost-efficient, and reliably executable solution for your application.

Typical challenges we address already in the planning phase:

 

  • Selection of suitable cables, connectors, and materials for the respective application
  • Early prevention of wiring errors and contact issues
  • Alignment between technical feasibility, cost, lead times, and production scalability
  • Comprehensive technical consulting
  • Detailed drawings and specifications
  • In-depth evaluation of material selection for the specific application
  • Greater planning reliability from the outset
  • Fewer errors, less effort—thanks to well-thought-out design
  • Wire harness concepts suited for series production

Wire harness and cable assembly

Wire harness assembly requires sound development expertise, material expertise, and scalable production. Our goal: high-quality technical interconnection solutions that integrate seamlessly into your series processes. For existing customers, we also provide cable assembly services as part of harness manufacturing.

 

Our production process consistently considers tooling compatibility, compliance with standards, and full material certification of all components used. The precise assembly of connectors is carried out according to defined quality standards and validated testing procedures.

 

We manufacture both standard wire harnesses and cable systems for drag chain applications designed to withstand continuous mechanical stress. Production is tailored individually to your volumes, complexity, and delivery requirements. The result is robust, installation-ready cable systems with reproducible quality.

We take the following challenges into account during production:

 

  • Dynamic product adaptations
  • Complex specifications
  • Demanding crimping and connection technologies
  • Complex assemblies with diverse materials and connectors
  • Cutting, stripping, crimping, ultrasonic welding, overmolding
  • Custom adaptation of wire harness design to your current product development
  • Cost- and manufacturing-optimized design improvements
  • Creation or revision of specification drawings including golden samples
  • Automated, semi-automated, and manual processes according to delivery requirements
  • Time- and cost-efficient production
  • Maximum durability through carefully validated suitability and functionality
  • Precisely assembled, reliable, and installation-ready cable harnesses
  • Full transparency and traceability through specification-based documentation

Testing of cable assemblies and wire harnesses

Reliable cable systems are created through consistent validation. As part of our test engineering services, we develop suitable test processes to ensure that every assembly performs exactly as specified under defined conditions—with a strong focus on electrical testing and reproducible crimp quality.

 

By combining automated test systems with qualified manual procedures, we ensure transparency, traceability, and documented quality.

Testing cable assemblies and harnesses requires maximum precision, particularly to prevent:

 

  • Hidden or intermittent electrical faults
  • Defective crimp or solder joints
  • Loose connectors or contacts
  • Ensuring continuity testing, pull-force, and temperature stability to guarantee durability
  • Compliance with customer-specific standards and specifications
  • Production part approval process (PPAP)
  • Crimp height measurement and cross-section analysis
  • Torque testing of screws and connectors
  • Manual optical and X-ray inspections
  • Moisture and leak testing to ensure insulation integrity
  • Pull-force testing for ferrules, contacts, and connectors
  • First article inspection during production ramp-up
  • Sample-based outgoing inspections according to defined specifications
  • Fully electrically tested cable harnesses
  • Reduced failures and lower rework and troubleshooting costs
  • Reliable quality through specification-compliant production

End-of-Life Management for wire harnesses

Even after project completion, worn or obsolete components can affect your product and lead to unexpected costs. We support your products throughout their entire lifecycle, ensuring long-term operational reliability.

 

With structured lifecycle support, we ensure continuous spare parts availability, technical support, and predictable service processes—keeping your systems fully operational.

Challenges can also arise in later stages of the product lifecycle:

 

  • Worn or damaged components
  • Sourcing suitable replacement parts
  • Delays in maintenance or repair
  • Risk of extended downtime
  • Comprehensive warranty services
  • Reliable spare parts supply
  • Lifecycle support from delivery through to product discontinuation
  • Minimized downtime even after market launch
  • High operational reliability thanks to long-term spare parts availability
  • Long-term planning security through proactive lifecycle management
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Variosystems is your partner for wire harness and cable assembly

Are you planning a new project or looking for a strategic EMS partner for your cable systems? With our expertise in wire harness assemby, we support companies in Industrial & Automation, Medtech, and other demanding industries. From initial inquiry through development, industrialization, and life-cycle management, we support your project with deep technical expertise.

Send us your drawings and technical documentation, bills of materials (BOM), or technical specifications, including testing requirements and applicable standards. Based on this, we will prepare a tailored quotation.

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