Wire Harness, lead wire & Cable Assembly Manufacturing
Electro Controls designs and manufactures wire harness and cable assembly solutions for OEM manufacturers, industrial equipment companies, and automation integrators. Operating from a modern 90,000 square foot facility in Sidney, Ohio, our Wire Harness Division produces everything from individual lead wires and wire kits to complex multi-conductor harness assemblies used in demanding industrial environments.
Wire Harness & Cable Assembly Solutions for Every Application
- Every harness and cable assembly we produce is manufactured to customer-supplied specifications and subjected to robust inline conductivity and short circuit testing before it leaves our facility. That testing process is not a final checkpoint — it is built into the production workflow so issues are caught and resolved before they ever reach your line.
- Individual lead wires and wire kits (AWG down to 26AWG)
- Multi-conductor cable assemblies
- Industrial and OEM equipment harnesses
- Recreational vehicle body harnesses
- High flex robotic interconnect cables
- Battery & welding cable terminations (AWG up to 500MCM)
- Power cord assemblies (NEMA plug/receptacle configurations)
- Large cable lugging and assembly
- Ultrasonic wire welding and solder capability
- Wide range of terminal manufacturers and tooling
Advanced Wire Processing Technology for Consistent, High-Quality Output
Maintaining quality at volume requires more than skilled labor — it requires the right equipment. Electro Controls has invested in automated wire processing technology that handles cutting, stripping, crimping, and labeling with precision and consistency across every run.
Automated wire processing reduces variability, minimizes manual error, and ensures that every wire in your assembly meets the same dimensional and electrical standards. Our capabilities support a wide range of terminal manufacturers and tooling configurations.
Contract manufacturing From First Article to Production Shipments
Bringing a new product to market often means working through multiple design iterations before settling on a final harness configuration. Electro Controls supports that process by offering product development assistance and prototype builds within the Wire Harness Division.
Working with a single manufacturing partner from prototype through production reduces lead times, simplifies communication, and ensures that the team building your production harnesses is the same one that helped develop them. That continuity translates into fewer surprises and faster ramp-up when it is time to scale.
Delivery Programs Designed Around Your Production Schedule
For OEM manufacturers, a late harness delivery can shut down an entire production line. Electro Controls supports Kanban and Just-In-Time (JIT) delivery programs to prevent that from happening — working from your production schedule and sales forecasts to ensure assemblies arrive when and where you need them, without requiring you to carry excess inventory.
UL Certified Wire Harness Manufacturing
Electro Controls holds multiple UL certifications covering wire harness and cable assembly production, including UL listings for cord assemblies and wire harnesses. Our facility also operates under an ISO 9001:2015 certified quality management system, which means the processes behind every harness we produce are documented, controlled, and continuously reviewed for improvement.
For OEM manufacturers that require documented compliance as part of their supply chain, Electro Controls provides the certifications and quality infrastructure to meet those requirements without added friction.
A Wire Harness Manufacturing Partner You Can Rely On
Electro Controls has been a trusted manufacturing partner for OEM companies and industrial equipment manufacturers since 1976. Whether you are looking for a long-term production partner or need support launching a new product, our team is ready to help you get there.