Cable Assembly
A drawing and design-for-manufacturing review is where a wire harness RFQ is de-risked before tooling. We red-line the drawing and BOM, flag connector, terminal, gauge, and spec gaps, propose approved alternates and cost-downs, and return a quote-ready manufacturability review — so a program is priced on real inputs, not on assumptions that fail at first article.
Application Context
Real customer engagements, anonymized to industry and region — no client names are published. The numbers are from the actual programs.
Earthmoving-equipment OEM · Australia — spec lock enables an accurate quote. A 200-piece harness RFQ was missing critical specs: relay models, Deutsch connector variants, and Hammond enclosure details. Rather than guess and risk a wrong quote or a production error, we returned a short spec-lock list; once those fields were fixed, an accurate 200-piece quote followed on the first pass. Read the full case study →
Logistics-technology OEM · Germany — incomplete BOM clarified. An initial BOM carried unclear material specifications that stalled quoting, alongside a components-only partial-fulfillment requirement. A structured BOM review resolved the ambiguity and let the order move with a flexible, clearly scoped build. Read the full case study →
Both show the same discipline: the drawing and BOM are made unambiguous before a number is committed — which is exactly what protects the quote and the first-article build. See more wire harness case studies.
What we review
For RFQ-stage buyers who want the drawing and BOM de-risked before a quote is treated as final.
Every connector, terminal, seal, wire, label, and protection part is checked for a real manufacturer part number, availability, and MOQ. Generic descriptions and missing part numbers are flagged, and approved alternates are proposed where the spec allows.
Circuit-by-circuit review of AWG, color, twist, and shield callouts against current, distance, and temperature. Gauge consolidation opportunities are identified, and any missing electrical data needed to size a wire is called out.
We confirm the acceptance class (IPC/WHMA-A-620 Class 1/2/3) and the test scope, because a Class 3 harness and a Class 2 harness with the same BOM are not the same quote. Ambiguous or missing acceptance criteria are flagged before pricing.
Branch lengths, routing, fixture-board needs, crimp tooling, and overmold or backshell requirements are checked so tooling cost is separated from unit price and nothing surprises the shop floor at build time.
Engineering Challenges
Unspecified relay models, connector variants, or enclosure details prevent an accurate quote and risk a production error. We return a spec-lock list so the drawing is unambiguous before a number is committed.
A "4-pin waterproof connector" with no part number forces a guess or a clarification loop. We convert generic entries into verified part numbers with availability and MOQ before pricing.
Gauge over-specification, avoidable splices, and single-source connectors quietly raise cost. A review surfaces gauge consolidation, splice elimination, and approved alternates while they are still cheap to change.
Without a stated acceptance class, a quote is either padded to assume Class 3 or blocked on a question. We confirm the class and test scope so the quote reflects the real requirement.
Technical Capabilities
Manufacturing Process
Quality & Testing
The cheapest place to fix a harness problem is on the drawing, not on the floor. A DFM review moves connector, gauge, test-class, and tooling questions to the front of the program — documented so engineering, purchasing, and supplier quality work from the same unambiguous inputs before the first build.
Why WHP
A drawing review is only useful if it comes from people who build the harness — not from a form that just reprices your BOM.
The red-line comes from the same team that crimps, tests, and ships the harness, so the questions are about how the part actually builds — connector fit, crimp tooling, test coverage — not just line-item repricing.
Missing specs, generic BOM entries, and allocated connectors are flagged up front with approved alternates, so a quote is priced on confirmed inputs instead of assumptions that fail at first article.
Gauge consolidation, splice elimination, and terminal-family alternates are returned with the review because a cheaper, more manufacturable harness is a better program for both sides.
We review customer-controlled drawings, BOMs, materials, and test plans for manufacturability. We do not provide CAD or schematic-creation services — the design stays yours; the manufacturability risk becomes visible.
A manufacturability review still needs shared quality language, so buyers can align RFQ wording with IPC/WHMA-A-620 workmanship, UL-758 wire context, and documented ISO 9001-style controls before supplier comparison.
FAQ
OEM Program Entry
Send the drawing, BOM, wire list, acceptance class, and quantity. We will return red-line questions, part-number verification, approved alternates, cost-down options, and a quote-ready manufacturability review.
Related Capabilities
Services that pair with an RFQ-stage drawing and DFM review.
TL;DR
A DFM review red-lines your drawing and BOM before a quote is treated as final.
It verifies connector/terminal part numbers, wire gauge, test class, and tooling needs.
Cost-downs — gauge consolidation, splice elimination, approved alternates — come with the review.
We review build-to-print / customer-controlled drawings; we do not create your CAD or schematic.
Applications
Best for OEM teams that want the drawing and BOM de-risked before a quote — or a tooling spend — is committed.
First-time harness quotes where a manufacturability review prevents a wrong price and a first-article surprise.
Harnesses moving to a new supplier, where the drawing and BOM must be re-verified against the new build line.
RFQs blocked on ambiguity — missing part numbers, undefined class, generic connectors — that a spec-lock resolves.
High-mix programs with frequent revisions where a review keeps connector and gauge questions ahead of the build.
Existing harnesses being re-quoted, where gauge consolidation and terminal alternates lower landed cost.
Programs about to commit tooling, where a final manufacturability check protects the tooling investment.
RFQ Package
Standards
A manufacturability review still needs shared quality language. Public references help buyers align RFQ wording with IPC/WHMA-A-620 workmanship expectations, UL wire context, and documented ISO 9001-style controls before supplier comparison.
Background for the association behind cable and wire harness workmanship standards used in supplier-quality discussions.
Reference context for buyers reviewing wire, insulation, and component safety language in a harness RFQ.
Reference context for documented quality-management systems and repeatable release records.
Reviewed by
Founder & General Manager, WellPCB