Tag Archive for Automation

You Asked: “When should we automate?”

Automation is a big step most manufacturing companies consider at one point in time. There are a distinct advantages which include improved quality and more accurate piece to piece consistency.

This question to automate is frequently asked. Is there a trigger that pushes you to make a decision to invest in automation? Are there signs leading to that decision? We will address these topics in this post. First a short answer and following some points to consider.

The short answer is no. There are no defined rules to move you into automation. Every company and their business conditions are different. Some will move quicker to automate while others integrate automation much slower.  Volume per batch is less of a consideration. Annual production volume is a greater consideration.

There is a sliding scale to automation. In general, any production above manual hand tool processing can be considered automation. For a perspective on a migration path from manual to automated processing, consider Methods of Processing Wire Assemblies. For the basis of our discussion, we are focusing on the migration from semi automating processing of wire (measure, cut and strip using single or multi-stage bench top machines) to an automated work center.

Elements of wire processing automation

The most basic of processing automation is the measure, cut and strip of wire and crimp of terminals on one or both ends. But automation allows for other processing possibilities. Typical secondary processing options include:

  • Tin tipping of wire
  • Ultrasonic tipping of wire
  • Weather seal application.
  • Wire doubling.

small splice

Ultrasonic wire tipping


Weather Seal Application

Current or future processing should include an evaluation of processing wire leads using the above secondary processing. This makes justification easier to achieve and gives the company an indication of the scope of machine solution needed.

Set up time and job lot sizes.

In the past, automation was justified based on one or several large production runs. That was due to the time it took to change from one set up to the next. Pneumatic motions and bolted in production tooling gave way to programmable servo motors and quick change tooling bases. Therefore it is easier to run smaller lots with less machine down time than in the past.

With production rates in excess of 3,000 pieces per hour on short wire lengths, there still needs to be a reasonable lot size.  Providing a recommended lot size would not be useful as companies consider a range of minimum lot sizes. You just need to balance the set up time with the lot size and the acceptable number of set ups per day.

Labor Savings.

There is a potential for significant labor savings when moving to automation. But consider that the personnel that operate the automation systems need to be trained in the machine operations, the software and use of a micro processor communication interface. Also consider maintenance resources.

Conditions Triggering a move to Automation.

Typically there are two conditions that we see when companies migrate to automation.

  1. Business Growth. This is a slower movement towards the point where the decision to automate occurs. Available resources in capital funding, facility floor space space and the need to reduce direct labor content will converge to make a seamless decision to automate.
  2. New Contract. When the company receives a substantial contract for a specified duration, the decision is quicker.

Floor space can be a factor that speeds up or slows down the decision to automate. Limitation of floor space to accommodate the new machine installation can be an issue. Re-locating to a larger facility may be part of a larger business strategy that includes new automation investment. Often it is a balance between the distribution of labor, overall direct labor costs and the availability of floor space.


As stated from the beginning, automation is a big step in any company large or small. Considering global annual production of wire assemblies that are processed is more important than large lot sizes due to the reduced set up time with newer technology processing machines. Redeployment of labor, training personnel in set up operation and maintenance are critical factors. Where a decision to automate is made from a new large volume contract, the duration of the contract is also an important factor.

When these elements are considered and in conjunction with good advice from outside sources, the migration to automation is a low risk proposition. WireProcess can provide the direction you need and the solutions required to fulfill your automation requirements. Connect Your Way to WireProcess.

Automated Wire Processing – Part One.

Processing wires for wire harnesses and cable assemblies is typically done using a combination of hand tools, single process bench tools and fully automated processing machines. Considering an automated wire processing solution is a big step for most companies who primarily use hand or bench tools. The outright cost and global production volumes are two important factors in considering an automated solutions. Overall production lost size is a factor to a lesser degree given the advances in servo motor technology and quick change processing tools.

Wire Process Specialties is pleased to present the Primo XLT, an automated wire processing solution from Schaefer Megomat.

The Primo XLT is priced at an entry level but contains features normally seen in more higher end processing machines. The Primo XLT has four processing stations, two on each side of the machine for flexible processing capabilities. Two MP2.0 (2 ton) crimp presses are included with quick change mini style adaptor plates. The 10 m/second wire feed speed is comparable to other premium machines on the market. Uncompromising repeatability and precision of the Primo XLT provides outstanding price to performance ratio.

With programmable servo motions, the Primo XLT has the capability to process different wire assemblies by mounting auxiliary processing tools. Wire doubling (two wires in one crimp) and twist/flux/tin are commonly used tools. Mount one or two Schaefer SSM weather seal modules to the Primo XLT and you have one of the lowest cost machines in the market for applying weather seals to one or both sides of a wire.

For complete specifications on the Primo XLT, click here.

Wire Process Specialties and Schaefer Megomat have the solutions to solve your wire processing problems. Contact Your Way to WPS to get the information you need to assess your company’s automation readiness to implement automated wire processing in your facility.

Part Two (coming soon) covers extended automation processing possibilities with the Schaefer Megomat Uno.