What is a Wire Harness?

A wire harness is a structured assembly of electrical wires and cables that routes electrical power throughout a vehicle like in a car, airplane, or other electronic device. The purpose of a wire harness is to effectively organize and connect electrical components with the correct wires. Typically, a wire harness has multiple conductors and connectors made from insulated wires and cables.

Depending on the components included, the harness can include multiple complex architectures, such as multiple twisted pairs, shielded twisted pair, coaxial cables, and more.

Each wire in the harness carries a specific type of current or signal, and is color-coded to prevent mix-ups.

The Wire Harness Manufacturing Process Includs

Designing: This step involves designing the wire Harnesses based on the specifications provided by the customer. In this step, the number of wires, their size, shape, color, and any special requirements are all finalized by an experienced professional.

Prototyping: Once the design is finalized and completed, the prototype model is created. This is sometimes done with help of CAD software. Then, the prototype is tested to make sure that it meets the specifications and requirements of the customer.

Production and Assembly: After testing, the final product is assembled. I.e., Each wire is connected to its respective connector and the connectors are connected accordingly.

Testing: Once the wire harness is installed, it is tested again to ensure that it works properly. A test jig is manufactured to test the connections for short circuit etc and to finalise the FAI Any problems discovered at this stage are corrected before the wire harness is shipped out to the customer.

In order to adequately create a wire harness, the individual wires and cables must be connected, fastened, and organized in the right order to ensure the device will function properly. The wires must be crimped, heat-shrinked, or soldered securely to maintain proper conductivity. Additionally, the wires must be organized neatly so the entire harness is easy to install and maintain.


A wire harness is a collection of electrical wires that connect various devices together. It helps to organize and protect these wires, which makes them easier to manage. In addition, best wire harness manufacturers in India, make it possible for the user to easily access each individual wire without having to disconnect any others.

The wiring harness is basically a bundle of insulated copper wires that have been bundled together.

Difference between Wire Harness & Cable Assembly:
Wire harness
Designed to carry electricity from one device to another
It made up of individual wires that are bundled together
It is not waterproof and might requires additional layer of covering.
It is Flexible
Cable Assembly
Cable assembly is designed to carry electricity between different types of devices.
It is a single cable assembly contains many cables that are bundled together.
 Water-resistant cable assembly can be designed to protect the cables from moisture.
Cable assembly is rigid and inflexible


The traditional type of wiring harness, sometimes referred to as a harness, typically consists of bundles of multi-stranded signal and power wires, tightly wound and wrapped with insulating material. The harness can contain components such as relays and sensors, etc.

  • Cross-linked or braided wiring harnesses are usually used in more complex or advanced electronic systems and they provide much greater electrical protection than traditional wiring harnesses.
  • Modular wiring harnesses provide the most efficient power transfer from one component to the next. This type of harness utilizes a series of flat cables or wires that are connected and maintained in a stacked configuration.
  • Robotically assembled wiring harnesses provide an even greater level of efficiency. This type of wiring is fully automated using robotic arms and specialized software. It can be customized quickly with minimal setup and resources.

Zastata manufacturer’s also expertise in the manufacturing of specific types of harnesses based on their application like, Flat harnesses, Ribbon Harnesses, EMI Shielded Harnesses, RF Harnesses.

Quality Documentation

Zastata has good understanding and experience with Quality documentation like:

APQP – Advanced Product Quality Planning
FMEA – Failure Mode Effective Analysis
PPAP Level 3 – Production Part Approval Process
SPC – Statistical Process Control
MSA – Measurement System Analysis

Quality Certifications

We work with manufacturers who hold certifications like:

ISO 9001:2015 (Quality Management System)
ISO 14001:2015 (Environmental Management System)
ISO 45001:2018 (OH & SMS)
AS9100 Rev C (Aviation, Space and Defence)
ISO13485:2016 (Medical Devices)
IATF16949:2016 (Automotive Quality Management System)


Untitled design (75)


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EMI Shielded Harnesses


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Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.


Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.










The benefits of using wire harnesses is

  • It enables complex circuitry to be simplified and condensed into a single unit.
  • Requires Simplified production, installation, and servicing of the electronic device.
  • It reduces the potential of problems and interference that are caused by multiple wires running through an electronic device.

Wire harnesses are commonly found in manufacturing, aerospace, automotive, and retail electronic products. They are used for several different applications, all requiring efficient organization of wiring components.

  • In a car’s interior, a wire harness is used to power the instruments, gauge systems, and other systems.
  • In aircraft, a wire harness is used to provide power and data communications to the flight systems and avionics.
  • In the retail industry, wire harnesses are used in home appliances, computers and other consumer electronics.

In conclusion, a wire harness is an essential element of manufacturing a working product, be it in aerospace, automotive, or retail electronic products. It helps to effectively organize, fasten, and connect electrical components with the correct wires, reducing potential wiring complexities and potential problems. Zastata makes sure that wire harness manufacturers do a thorough test using test jigs before shipping out.




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