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How Early CM Involvement Lowers Total Cost of Ownership in Cable & Wire Harness Manufacturing

  • Sean Campbell
  • Dec 10
  • 2 min read

Many OEMs involve their cable assembly contract manufacturer only after drawings are finalized. While this seems efficient, the late-stage handoff often reveals issues that lead to engineering changes, preventable delays, and increased costs.


Engaging your CM earlier in the design process ensures better manufacturability, more reliable component availability, accurate cost forecasting, and a smoother transition into production. Early collaboration ultimately lowers the total cost of ownership for cable assemblies and wire harnesses.


Worker assembling complex wiring on a large board in a workshop; focus on multicolored wires and connectors, blurred background.

The High Cost of Late-Stage Engineering Changes


When your CM reviews designs only after the “handoff,” they may discover issues that require updates such as:


  • Incompatible connector selections

  • Difficult-to-manufacture tolerances

  • UL-listed wire availability issues

  • Unoptimized tooling

  • BOM inconsistencies

  • Incomplete drawings or unclear callouts


Each correction creates:


  • Delays

  • Re-quotes

  • Scrap/rework

  • Frustration between engineering, purchasing, and the CM


These problems compound during production scaling.


Benefits of Early Engagement with Your CM in Cable and Wire Harness Manufacturing


1. DFM (Design for Manufacturability) Collaboration


Your CM can help refine:


  • Connector and terminal selection

  • Pinout configuration

  • Assembly routing

  • Overmold considerations

  • Crimp tool specification

  • Wire type and insulation selection


DFM early on prevents costly rework and stabilizes production.



2. Component Availability & Supply Chain Planning


Global supply constraints remain unpredictable. Early CM involvement helps ensure:


  • Wires and connectors are globally available

  • Long-lead materials are reserved early

  • Obsolete components are replaced before design lock

  • Future volume pricing is not restricted by supply issues


Sanbor Manufacturing’s multi-regional footprint allows OEMs to select cost-competitive sourcing locations and avoid region-specific shortages.


3. Accurate Cost Forecasting & All-In Price Certainty

Sanbor Manufacturing provides:



OEMs gain predictable long-term pricing, which is a valuable advantage when global trade conditions shift.



Example Scenario (Generalized)


An OEM submits a nearly finalized cable assembly design. The CM identifies that the specified connector is end-of-life and only available in limited regions. By reselecting a globally available connector early, the OEM avoids:


  • A six-week delay

  • 25–30% cost increase

  • Major ECO documentation


Early CM collaboration pays for itself immediately.


How Sanbor Manufacturing Supports Early-Stage Engineering


Sanbor provides extensive early-stage support across cable assemblies, wiring harnesses, PCBAs, and turnkey builds. This includes:


  • NPI engineering reviews

  • Manufacturability feedback

  • BOM and drawing optimization

  • Tooling and automation planning

  • Coordinated engineering across global facilities

  • Standardized quality systems


Combined with all-in price certainty, OEMs gain predictable and scalable cable and wire harness manufacturing across global markets. Early contract manufacturer (CM) collaboration is a competitive advantage. When engineering, purchasing, and manufacturing align early, total cost of ownership drops significantly.


Learn more about our global cable assembly manufacturing solutions for OEMs, and how Sanbor’s early involvement reduces total cost of ownership.


Ready to talk: Call 610.530.8500, email sales@sanbormfg.com or connect through our quick online contact form.

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