What is Mold Tooling?

Mold tooling is all about creating the molds we use in injection molding. It’s a manufacturing process that shapes molten plastic resins using metal molds. The terms "mold" and "tooling" are pretty much interchangeable when referring to these essential components in the injection molding process.

What types of molds do you specialize in?

We cater to a variety of injection molds, including multi-cavity hot runner molds, single and multi-daylight molds, collapsible core molds, and threaded parts, among others. We’ve got the expertise to handle a wide range of industry requirements.

Do you offer prototype tooling?

Yes, we do! We provide prototype tooling mainly to help evaluate prototype parts before you invest in production tooling. However, keep in mind that our primary focus is on high-volume molding, so the number of production parts from a prototype tool is usually limited.

How long does it take to build an injection mold?

The timeline for building an injection mold really depends on how complex the design is. Generally, you can expect it to take around 7-10 weeks on average.

What do you require for a new molding project?

Since we specialize in high-volume projects, we usually need a minimum order of 1 million parts. Plus, the item should be suitable for injection molding and made from materials that can be molded in this way.

What’s the mold development process like?

Here’s a quick rundown of our mold development process: We start by evaluating your part design and making any necessary adjustments for efficient molding. Then, we build the mold based on that design. Finally, we test the mold in our injection molding press to produce your production parts. On average, this entire process takes about 7-10 weeks.

What material should I use for my project?

Choosing the right material is often specific to your application. If you’re not sure which material to go with, no worries—we’re here to help and can offer some solid recommendations.

How can I access your services?

Getting in touch is easy! You can email us at sales@mefron.com or give us a call at +91- 079-66111038. Our team is ready to assist you with any questions or needs you have.

Do you provide project consultation?

Absolutely! We’re happy to provide project consultation. Just let us know what you need, and we’ll guide you through the process to make sure everything goes smoothly.

Where is your company located?

We’re based in Ahmedabad, Gujarat, India. Plus, we have sales offices in various top-tier cities to ensure we’re accessible to our clients.

The Strategic Alliance of Automotive OEMs and Wire Harness Manufacturers

09 April, 2025 Posted by Meghdip Pancholi

Rapid innovation defines today's automotive industry, with widespread adoption of complex systems like electric powertrains, advanced driver-assistance systems (ADAS), connected services, and sophisticated infotainment units. Integrating these technologies dramatically increases the vehicle's electronic complexity, requiring robust networks for power distribution and data communication. The automotive wire harness forms the backbone of this electronic revolution as it serves as the highway for the data and electric systems of the automobile, functioning melodiously within the structure of the vehicle.

The Critical Role and Growing Complexity of Automotive Wire Harnesses

A harness is a compact collection of wires, terminals, and other connectors that power and connect automotive components such as microcontrollers, sensors, and actuators. It is also called the nervous system of the vehicle. Each modern-day vehicle features cutting-edge electric automobile control units (EACUs) and demands complicated subassemblies of remarkable standards. There are estimations that a high-feature modern vehicle is capable of holding up to a mile of wiring.

The speeding up of the pace adds tremendous stress on an automotive OEM business undertaking as managing dependency in-house has increasing difficulties. In particular, achieving reliable forecasts in tandem with managing controls for the production in scale for dependable and complex wire harnesses makes complete in-house control increasingly difficult to sustain. Therefore, strategically partnering with an Electronics Manufacturing Services (EMS) provider that specializes in wire harness assembly is highly advantageous for optimization and offers the right specialization for the customized demands of the business.

Why In-House Wire Harness Manufacturing Struggles to Keep Pace?

Many OEMs significantly struggle with managing wire harness production internally. These issues influence cost, quality, and time-to-market:

Bottlenecks in Scalability and Production Flexibility: Meeting market demand for different variants or models of a product poses one of the greatest operational hurdles. Optimistic cycles spend capital on equipment, floor space, and skilled workforce. Resources need to be stationed, often accompanied by long lead times. On the other hand, pessimistic cycles often dominate, leading to painful underutilization.

Ensuring Consistent Quality and Meeting Stringent Automotive Standards: The automotive industry demands high quality. Maintaining correct connections, crimps, and wire placements on all harnesses exceeds thousands, which requires rigorous quality control systems. The consistency of adherence to ISO/TS automotive wiring standards such as IATF 16949, which oversees the quality management part of the control system in the automotive industry, is painstakingly demanding when it comes to processes and testing. The consequences of failures such as reworks, warranty claims, or recalls can be incredibly costly.

Achieving Comprehensive Material Traceability: The intricacy of the harness contains hundreds of parts, including wires, terminals, connectors, clips, and tapes. Following each part to its origin batch is a logistical hurdle. Nonetheless, in the case of no compliance being met, streamlined problem resolution, or assurance, absolute traceability is a necessity.

Investing in and Implementing Advanced Process Automation: Investment in new technology enhances the efficiency and accuracy of wire cutting, stripping, crimping, block loading, and electrical testing. However, acquiring, implementing, and maintaining this specialized equipment represents a major capital expenditure and requires a workforce with specific technical skills.

Managing a Complex Supply Chain: The need to source a large variety of specialized wires, connectors, and other components from multiple suppliers while managing risks of inventory shortages or obsolete stock enhances complexity further and strains procurement resources.

Boosting Efficiency in Automotive Wire Harness Manufacturing through EMS Partnership Advantage

Partnering with a specialized wire harness EMS partner directly addresses these in-house challenges, offering a strategic path to optimization:

Gaining Instant Scalability and Flexibility: Operating capabilities access to a well-established EMS provider offers instant scalability and flexibility because optimized manufacturing capacity is readily available. The infrastructure and workforce can increase or decrease production levels depending on OEM forecasts. It enables OEMs to adapt to changes in demand without incurring additional capital expenditures. A dedicated partner like Mefron provides automotive cable assembly manufacturing with flexible CAD systems tailored for optimized scalability relative to project requirements.

Leveraging Expert Quality Control and Compliance (ISO/TS Standards): Quality is paramount for specialized EMS providers. They function under robust Quality Management Systems (QMS) for electronics manufacturing. One of the measurements for their quality is certification they have. For credible automotive EMS providers, IATF is essentially non-negotiable. These partners employ advanced QC departments that apply sophisticated AOI (Automated Optical Inspection) and rigorous electrical test inspection methods. Mefron also maintains a rigorous quality management system(QMS) to satisfy the stringent automotive quality benchmark.

Implementing Robust Material Traceability Systems: Experienced EMS partners normally utilize advanced Manufacturing Execution Systems (MES) or Enterprise Resource Planning (ERP) systems, which offer detailed component-level traceability. This streamlines compliance reporting, improves quality control processes, and allows rapid confinement if there is an issue with a component. Leverage Mefron's refined techniques to harness unconstrained custom cable harness solutions and enjoy seamless traceability.

Accessing Cutting-Edge Process Automation: Through collaboration with EMS, Original Equipment Manufacturers (OEMs) tap into the provider's automation on major processes like wire processing, termination, and continuity/electrical testing. This means improved consistency and yields, faster throughput, and often more predictable costs for your automotive wire harness manufacturing requirements. Mefron employs advanced techniques for critical wire harness processes in every assembly to achieve more reliable and predictable outcomes.

Streamlining Supply Chain Management: EMS providers work with intricate supply chains on a daily basis. These professionals have well-established links with suppliers and manufacturers, possess powerful buying authorizations, and have competencies in parts engineering. They also manage component life cycles and have sourcing alternatives. By utilizing Mefron's capabilities to source custom wire harness components and other superior parts, the procurement process gains reliability.

Contact with our experts today to discuss your unique needs and explore how we can help you with custom wire harness solutions.

Let's Talk!

Selecting the Right EMS Partner for Your Automotive Wiring Harness

Picking the right EMS provider is crucial for establishing a productive partnership. Consider the following important points:

Technical Skills and Manufacturing Capabilities Evaluation: Ensure they have the types of equipment, processes, and technical expertise needed to process wire harnesses. Check whether they are dealing with intricate custom cable harness solutions. Evaluate their ability to provide feedback on the manufacturability of your designs to ensure efficient production.

Review Testing and Quality Management Systems: Deep dive into their QMS. Ask detailed questions about their testing procedures (e.g., continuity, hipot, pull tests), inspection points throughout the assembly process, process controls, and documentation practices for automotive cable assembly.

Evaluate Scalability and Capacity: Determine if the potential partner currently has production volume capabilities and the flexibility to meet the project's anticipated growth.

Prioritize Communication and Partnership Approach: Prioritize strategic partnership with a provider that emphasizes transparency, maintains clear and proactive communication channels, and demonstrates a collaborative approach to problem-solving.

Drive Future Success with a Strategic EMS Partnership for Wire Harness Assembly

In the automotive industry, productivity is critically important at all levels of the chain. Working with a dedicated EMS partner offers strategic advantages for wiring harness services, one of the most sophisticated and crucial processes in the automotive industry.

By selecting Mefron as wire harness EMS partner, you can take advantage of external capabilities and infrastructure, sophisticated technology, and industry-class level supply chain integration. This will benefit OEMs with quality engineering, cost, and scalability.