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Cable And Wire Harness Assemblies
Engineered For Reliability
From simple cable assemblies to complex multi-breakout harnesses, we engineer, build, and test every connection to IPC/WHMA-A-620
standards. Automated cutting, crimping, and 100% continuity testing across every unit, every run.
Trusted by teams that can’t afford failure
1
M+
Connections per year
100
%
Continuity tested
< 50
PPM
Defect rate
Pull
Force verified
IPC/WHMA
A-620 Class 2 & 3
Every wire harness and cable assembly capability. One expert partner.
From a single prototype harness to a 10,000-unit production run, we build connections that organise, protect, and secure your product's critical wiring with precision and consistency.
Wire harness manufacturing
Custom cable assemblies
Automated crimping
Connector overmolding
Electromechanical assemblies
Prototype & NPI support

Also available: Drop-shipping direct to your end customer, we can fulfil orders directly from our facility, reducing your logistics overhead and time to end-user.

Wire harness manufacturing
Complex form-board harness assembly with multi-breakout routing, lacing, and abrasion protection engineered for the specific demands of your application.
  • 1:1 scale form-board routing
  • Multi-breakout and branching harnesses
  • Lacing, sleeving, and conduit protection
  • PC/WHMA-A-620 Class 2 & 3
Custom cable assemblies
Multi-conductor cables, coaxial, and ribbon cable assemblies - cut, stripped, and terminated to length with full connector compatibility.
  • Multi-conductor and shielded cables
  • Coaxial and ribbon cable assemblies
  • Compatible with TE, Molex, JST, Amphenol
  • Cost-effective connector alternatives available
Automated crimping
Semi-automatic and fully automatic crimping with integrated crimp force monitoring (CFM) ensuring a gas-tight crimp and verified connection on every terminal.
  • Automated crimp centres with CFM
  • Crimp height measurement & pull-force verification
  • Consistent quality across high-volume runs
  • Full process traceability per connector
Connector overmolding
Low-pressure molding (LPM) and overmolding for IP-rated strain relief and durability protecting connections in harsh, high-vibration, or moisture-exposed environments.
  • Low-pressure molding (LPM)
  • IP-rated strain relief solutions
  • Suitable for automotive, industrial, outdoor
  • Custom profile and material options
Electromechanical assemblies
Wire harnesses integrated with electromechanical components - terminals, relays, connectors, and enclosures for complete sub-system assemblies ready for integration.
  • Harness and component integration
  • Terminal and relay assembly
  • Ready-to-integrate sub-assemblies
  • Tested to functional specification
Prototype & NPI support
Small-batch prototype builds and structured NPI support so you can test and validate your harness design before committing to full production tooling.
  • Small-batch builds from 1 unit
  • Free sample evaluation and quoting
  • Connector alternative suggestions for cost down
  • Seamless scale-up to production
Every wire harness and cable assembly capability. One expert partner.
From a single prototype harness to a 10,000-unit production run, we build connections that organise, protect, and secure your product's critical wiring with precision and consistency.
Wire harness manufacturing
Wire harness manufacturing
Complex form-board harness assembly with multi-breakout routing, lacing, and abrasion protection engineered for the specific demands of your application.
  • 1:1 scale form-board routing
  • Multi-breakout and branching harnesses
  • Lacing, sleeving, and conduit protection
  • PC/WHMA-A-620 Class 2 & 3
Custom cable assemblies
Custom cable assemblies
Multi-conductor cables, coaxial, and ribbon cable assemblies - cut, stripped, and terminated to length with full connector compatibility.
  • Multi-conductor and shielded cables
  • Coaxial and ribbon cable assemblies
  • Compatible with TE, Molex, JST, Amphenol
  • Cost-effective connector alternatives available
Automated crimping
Automated crimping
Semi-automatic and fully automatic crimping with integrated crimp force monitoring (CFM) ensuring a gas-tight crimp and verified connection on every terminal.
  • Automated crimp centres with CFM
  • Crimp height measurement & pull-force verification
  • Consistent quality across high-volume runs
  • Full process traceability per connector
Connector overmolding
Connector overmolding
Low-pressure molding (LPM) and overmolding for IP-rated strain relief and durability protecting connections in harsh, high-vibration, or moisture-exposed environments.
  • Low-pressure molding (LPM)
  • IP-rated strain relief solutions
  • Suitable for automotive, industrial, outdoor
  • Custom profile and material options
Electromechanical assemblies
Electromechanical assemblies
Wire harnesses integrated with electromechanical components - terminals, relays, connectors, and enclosures for complete sub-system assemblies ready for integration.
  • Harness and component integration
  • Terminal and relay assembly
  • Ready-to-integrate sub-assemblies
  • Tested to functional specification
Prototype & NPI support
Prototype & NPI support
Small-batch prototype builds and structured NPI support so you can test and validate your harness design before committing to full production tooling.
  • Small-batch builds from 1 unit
  • Free sample evaluation and quoting
  • Connector alternative suggestions for cost down
  • Seamless scale-up to production
Connector brands we work with
Cable and Wire harnesses built for
your industry's specific demands
Different industries have fundamentally different harness requirements - temperature range, vibration tolerance,
chemical resistance, compliance standards. We bring sector-specific expertise to every programme.
Automotive
High-vibration, temperature-rated harnesses - IPC/WHMA Class 3, full traceability
Industrial machinery
Ruggedised assemblies for continuous operation in harsh factory environments
Renewable energy
UV-resistant, weatherproof harnesses for solar, wind, and energy storage systems
Medical Devices
Clean-room compatible, biocompatible materials, documentation for regulatory compliance
Telecom & networking
High-reliability signal and power harnesses for infrastructure equipment
Consumer electronics
Compact, lightweight assemblies at high volume with consistent cosmetic quality
Six steps to a verified, production-ready harness
Every harness we build follows a structured, documented process with quality checkpoints at every stage so issues
surface early, not in the field.
  • 1 Cut & strip
  • 2 Termination & crimping
  • 3 Form-board assembly & routing
  • 4 Pull testing
  • 5 100% continuity & HiPot testing
  • 6 Label, kit & pack
Cut & strip
Automated processing ensures consistent wire lengths and defect-free stripping across every wire in the harness eliminating the variability of manual cutting at any volume.
Cut & strip
Termination & crimping
Semi-automatic and fully automatic crimping with integrated crimp force monitoring (CFM) validating every crimp to ensure a gas-tight, mechanically secure connection on every terminal.
Termination & crimping
Form-board assembly & routing
Wires are routed on 1:1 scale form-boards following exact harness geometry with lacing, sleeving, conduit, and abrasion protection applied at each breakout point.
Form-board assembly & routing
Pull testing
Regular tensile strength verification on crimp samples to validate tool calibration ensuring mechanical integrity is maintained consistently across production runs.
Pull testing
100% continuity & HiPot testing
Every completed harness is tested on automated test boards checking for opens, shorts, miswires, and insulation integrity before any unit is approved for the next stage.
100% continuity & HiPot testing
Label, kit & pack
Clear identification labels, inkjet wire marking, and kitted packaging for line-side efficiency so your harnesses arrive ready to install, correctly identified, and damage-free.
Label, kit & pack
Automated precision on every line
Purpose-built wire harness equipment delivering consistent, measurable quality operated by IPC/WHMA-trained assemblers on every line.
Automated cut & strip machines
High-speed automated wire processing consistent cut length and strip quality across every wire, eliminating manual variability at volume.
Automatic crimp centres (CFM)
Fully automatic crimping with integrated crimp force monitoring validating every crimp in real time and flagging any out-of-tolerance connections immediately.
Automated continuity test boards
Digital test boards for 100% continuity, short, and miswire detection - every harness tested before leaving the line, no exceptions.
Low-pressure molding (LPM) system
Overmolding system for IP-rated connector strain relief protecting harness terminations from moisture, vibration, and mechanical stress in harsh environments.
HiPot testing equipment
High-potential insulation testing verifying dielectric integrity and insulation safety on every harness, critical for automotive and industrial applications.
Inkjet wire marking system
Automated inkjet marking for wire identification, colour-coding, and labelling ensuring every harness is correctly identified for installation and traceability.
Automated precision on every line
Purpose-built wire harness equipment delivering consistent, measurable quality operated by IPC/WHMA-trained assemblers on every line.
Automated cut & strip machines
High-speed automated wire processing consistent cut length and strip quality across every wire, eliminating manual variability at volume.
Automatic crimp centres (CFM)
Fully automatic crimping with integrated crimp force monitoring validating every crimp in real time and flagging any out-of-tolerance connections immediately.
Automated continuity test boards
Digital test boards for 100% continuity, short, and miswire detection - every harness tested before leaving the line, no exceptions.
Low-pressure molding (LPM) system
Overmolding system for IP-rated connector strain relief protecting harness terminations from moisture, vibration, and mechanical stress in harsh environments.
HiPot testing equipment
High-potential insulation testing verifying dielectric integrity and insulation safety on every harness, critical for automotive and industrial applications.
Inkjet wire marking system
Automated inkjet marking for wire identification, colour-coding, and labelling ensuring every harness is correctly identified for installation and traceability.
Why product teams choose JINST for wire harness assembly
A loose wire is a single point of failure. Here's why the teams who can't afford field failures choose us
Wire harness is in our DNA

Cable and wire harness assembly isn’t a side service – it’s one of our most established core capabilities, with dedicated production lines, IPC/WHMA-trained assemblers, and decades of cross-industry harness experience behind every programme we run.

100% continuity tested. Every unit.

No sampling, no exceptions. Every harness is tested on automated test boards before it leaves the line giving you complete confidence in every connection.

CFM on every crimp

Crimp force monitoring validates every single termination in real time not just sampled. A gas-tight crimp isn’t a target, it’s a verified outcome.

Integrated with PCB assembly & box build

Your wire harness programme can seamlessly integrate with PCB assembly and box build – all under one roof, eliminating handoff risk between suppliers.

Prototype to production - same team

From a single prototype harness to a 10,000-unit run, the same engineering team manages your programme throughout, ensuring nothing is lost in translation at scale-up.

Cost-down built into quoting

Our engineers actively suggest connector alternatives and material optimisations during quotin, identifying savings without compromising performance or reliability.

Built to standard. Tested to certainty.

Every wire harness and cable assembly leaves our facility having passed a structured quality
protocol aligned to IPC/WHMA-A-620 and your application’s specific requirements.

IPC/WHMA-A-620 Class 2 & 3

Workmanship standards applied across every assembly

Crimp force monitoring (CFM)

Every crimp validated in real time, not sampled

Pull-force testing

Tensile strength verified on samples to validate tool calibration

100% continuity testing

Opens, shorts, and miswires caught before any unit leaves the line

HiPot / high-potential testing

Nsulation integrity verified on every harness

Visual inspection

IPC/WHMA-trained inspectors check every assembly before despatch

Full unit traceability

Component, crimp, and test records maintained per harness

IPC/WHMA-A-620 Class 2 & 3

Workmanship standards applied across every assembly

Crimp force monitoring (CFM)

Every crimp validated in real time, not sampled

Pull-force testing

Tensile strength verified on samples to validate tool calibration

100% continuity testing

Opens, shorts, and miswires caught before any unit leaves the line

HiPot / high-potential testing

Nsulation integrity verified on every harness

Visual inspection

IPC/WHMA-trained inspectors check every assembly before despatch

Full unit traceability

Component, crimp, and test records maintained per harness

From import dependency to indigenous manufacturing - 100+ harness variants for a 5000 HP gas engine programme.
Problem:
A PSU and private oil & gas client was dependent on imported wire harnesses for a 5000 HP gas engine system driving up costs and creating critical supply chain risk.
Solution:
We reverse-engineered the harness, created full drawings and connection details, sourced domestic alternates to the same specification, and designed and manufactured 100+ harness variants entirely in-house.
Outcome:
100+ harness variants developed and manufactured locally, reducing cost and eliminating supply dependency for a critical industrial system.
100+ harness variants · 5000 HP engine · full import substitution
Read More
Ready to build your wire harness programme with us?
Send us your drawings, schematics, or a sample harness- our team will review and respond within 24 hours. We'll often identify cost-saving connector alternatives too.