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Scaling cable assemblies from prototype to volume production introduces new challenges in consistency, documentation, materials, cost control, and manufacturability. Without the right processes, OEMs often experience quality drift which are subtle variations that accumulate into performance issues, field failures, or certification setbacks. This guide explains how to prevent quality drift and achieve repeatable, stable cable production across global sites.

IPC/WHMA-A-620 is the globally recognized standard for cable assembly and wire harness workmanship. Most OEMs require their contract manufacturers to be certified but far fewer take the time to understand what the standard actually governs or how it should be applied in day-to-day production. That gap matters. Certification alone does not guarantee consistent quality, reliability, or long-term performance.

Many OEMs wait to engage their cable assembly contract manufacturer until the last possible moment — often after drawings are finalized and components are already specified. Unfortunately, this approach leads to avoidable delays, cost overruns, and engineering change orders (ECOs). Bringing your CM into the process early can reduce total product cost, accelerate lead times, and prevent downstream production issues.

As devices shrink and electronics become increasingly compact, OEMs face greater challenges when designing cable assemblies that fit and perform reliably within tight spaces. This article explores how proper bend-radius management, routing strategies, and strain-relief design help OEMs build compact, durable cable assemblies engineered for long-term performance.