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The manufacturing process for cable assemblies/wire harnesses at Romtronic is conducted in an environment that adheres to an established engineering-controlled processing workflow. Engineering reviews, controlled production processing, multiple levels of inspection, and validation testing are integrated into a single process.
By establishing this approach, Romtronic can be assured of the electrical reliability and mechanical stability of all cable assemblies produced, manufactured, and tested in accordance with clearly defined Technical Controls, rather than relying on individual production steps.
This workflow represents how engineering intent is translated into manufacturing execution.
Engineering Input & Feasibility Review
Each project starts with an engineering feasibility review that evaluates drawings, specifications, electrical requirements, mechanical constraints, environmental exposure, and regulatory requirements.
The review identifies Connector Systems, Cable construction, termination method, and Risk Points. At this point, engineering defines Technical Limits, Quality Requirements, and Validation Scope before submitting the Project for Production Planning.
This phase establishes the foundation for manufacturability, reliability, and traceability.
DFM Engineering & Process Architecture
Before materials enter production, manufacturing is engineered.
The product’s process architecture contains the following definitions: termination methods, overmolding methods, routing concepts, tooling strategies, inspection locations, and testing coverage.
All crimp methods, soldering profiles, EMI termination designs, and strain relief designs are established in accordance with equipment capability and are expected to perform over time.
This step determines how the product will be built, controlled, and verified.
Material Control & Traceability Setup
All incoming wires, connectors, terminals, and auxiliary materials are verified against engineering specifications.
Materials are batch-controlled, documented, and staged by project. Lot mapping links raw materials, tooling, inspection records, and production history to each manufacturing batch.
This traceability structure supports defect containment, regulatory compliance, and long-term quality analysis.
Core Manufacturing Operations
Manufacturing is executed through controlled process zones.
Operations for different product types include preparing products, performing wire processing, fully automated crimping, soldering, EMI termination of wires, integrating subassemblies into their respective products, overmolding, assembling wire harnesses, assembling housings, and completing mechanical finishes.
For each operation, engineers establish standards that define how the work is to be done, the tools used, and the required inspection frequency. All high-risk processes have been isolated, protected from defect propagation.
In-Process Quality Gates
Quality control is embedded within the workflow.
Monitoring of crimp forces, visual inspections with a CCD (charge-coupled device) camera, checks of solder appearance, audits of the manufacturing process, and electrical testing will be performed at various stages of production. Any deviation from specifications will be recorded immediately and sent to engineering for evaluation.
Quality gates can help stabilize quality and minimize defects that may go undetected until they reach the next stage of production.
Final Assembly & System Integration
Assemblies proceed through final routing, harness shaping, protection installation, labeling, and configuration verification.
Mechanical load paths, bend radii, shielding continuity, and connector orientation are verified during integration. Configuration control ensures that correct variants, revisions, and customer-specific requirements are maintained.
Electrical & Mechanical Validation
Completed assemblies undergo defined validation testing, which may include continuity testing, insulation resistance, hipot, contact resistance, functional verification, and mechanical pull-force testing.
Validation protocols are aligned with application risk, performance requirements, and customer or regulatory expectations.
Testing confirms that manufacturing execution matches engineering intent.
Final Inspection, Documentation & Release
Final inspection verifies workmanship, labeling accuracy, packaging integrity, and documentation completeness.
Production records, inspection data, and traceability documents are archived. Only assemblies that meet all engineering, quality, and documentation requirements are released for shipment.
Closed-Loop Engineering Manufacturing System
Romtronic’s manufacturing workflow operates as a closed-loop engineering system.
Production data feeds back into tooling calibration, documentation updates, risk assessment, and continuous improvement programs. This structure enables early drift detection, controlled process evolution, and long-term product stability.
Conclusion
A cable assembly is only as reliable as the system used to build it.
The hardware engineering manufacturing workflow at Romtronic encompasses the complete process from formal engineering drawings through manufacturing, including the following functions: Design Review (technical specifications); Manufacturing Process; Staged Inspection; Validation Testing.
Romtronic’s workflow assures that every cable assembly is manufactured, engineered, and controlled throughout its entire useful life.
