Cable assembly case studies below document real OEM supply programmes delivered by Nexharn Connectivity across industrial automation, medical devices, EV infrastructure, and data centre connectivity. Each cable assembly case study records the application specification, volume delivered, quality outcome, and cost result — giving procurement engineers verifiable evidence of Nexharn’s manufacturing capabilities before placing an enquiry.
For product and capability overviews, see our industrial cable assemblies, medical cable manufacturer, and EV battery cable assembly pages. Ready to start your project? Submit an RFQ — we respond within 24 hours.
Cable Assembly Case Studies by Industry
Data Centre Cable Assembly Case Study: MRJ21 Fan-Out — Netherlands Colocation
Industry: Data Centre / IT Infrastructure
Application: Top-of-Rack 24-port Ethernet fan-out from ISO-standard MRJ21 patch panels to individual server ports
Specification: MRJ21 to 24×RJ45 Cat6 LSZH fan-out assemblies, custom lengths 1.5 m and 3.0 m, RAL 7035 grey jacket, IP20 assembled
Volume: 1,300 pcs across two production batches (700 + 600 pcs)
Outcome: 41% unit-cost reduction versus prior European supplier; 6-week lead time from golden-sample approval; <0.4% defect rate across full delivery. Ongoing blanket order established for quarterly replenishment.
Medical Cable Assembly Case Study: ECG Lead Wire OEM Transition
Industry: Medical Devices / Patient Monitoring
Application: 5-lead ECG cable set for bedside patient monitor, IEC 60601-1 CF-type applied part classification
Specification: Medical-grade TPU jacket, silver-plated copper conductors, AHA snap connectors, 1.0 m lead wires + 0.9 m trunk cable; biocompatibility per ISO 10993
Volume: 2,000 pcs initial order; 6,000 pcs/year programme
Outcome: 38% cost reduction versus incumbent supplier; 99.6% first-pass acceptance at incoming QC; full ISO 13485-aligned documentation package (QMS records, FAI report, material traceability) delivered with first production lot.
EV Charging Cable Assembly Case Study: EVSE OEM — Germany
Industry: Electric Vehicles / EV Charging Infrastructure
Application: Mode 2 ICCB, Mode 3 tethered AC, and liquid-cooled CCS Combo 2 DC fast-charge cable assemblies
Specification: IEC 61851-1 / IEC 62196-2 / TUV CE certified; IP55 assembled; orange XLPE jacket for HV identification
Volume: 500 pcs Mode 2 + 300 pcs Mode 3 + 150 pcs DC fast-charge per quarter
Outcome: 37% cost saving versus German Tier-1 cable supplier; 6-step qualification process completed including factory video audit and golden-sample approval; CE Declaration of Conformity issued for all three SKUs. Serial production running quarterly.
Industrial Cable Assembly Case Study: HS-Link POF Replacement — KUKA KRC4 Fleet
Industry: Industrial Automation / Robotics
Application: HS-Link (POF) cable assembly replacement for KUKA KRC4 controller axis bus; KR AGILUS and KR QUANTEC models
Specification: 1 mm PMMA POF, KUKA-proprietary push-pull connectors, PUR flex jacket, lengths 4 m / 7 m / 10 m, IP40 assembled
Volume: 80 pcs/year on-demand maintenance programme for automotive press shop
Outcome: 100% KUKA-compatible confirmed via optical power budget test (attenuation <1.8 dB on all lengths); 5-business-day turnaround for urgent replacement stock; 23% cost saving versus original KUKA spare part pricing.
Automotive Wire Harness Case Study: EV BMS Sub-Assembly Qualification
Industry: Automotive / Electric Vehicles
Application: Battery Management System (BMS) low-voltage signal harness, 12 V nominal, 50-circuit, intra-battery-pack routing
Specification: XLPE insulation, PA66 connector housings (USCAR-2 pull-out rated), bundle diameter ≤22 mm; production environment: IATF 16949
Volume: 500 pcs pilot + 2,000 pcs/quarter serial production
Outcome: PPAP Level 3 documentation package accepted by Tier-1 OEM; process capability Cpk >1.67 on critical dimensions; on-schedule delivery for SOP. Ongoing serial production supply agreement signed.
Why These Cable Assembly Case Studies Are Relevant to Your Project
Each cable assembly case study in this collection demonstrates a repeatable, documented manufacturing capability — not a one-off project. The same qualification process, quality management system, and supplier coordination that delivered results across these cable assembly case studies is available to new customers under the same structured approach: specification review, golden sample approval, production with 100% testing, and complete documentation package.
The cable assembly case studies above span MOQs from 80 pcs/year to 2,000 pcs/quarter, and product types from precision POF robotics cables to high-voltage EV charging assemblies. If your project falls within these parameters, submit an RFQ and we will respond within 24 hours on business days.
For further technical background, read our cable assembly resources library or visit the how to order cable assemblies page for process and lead-time information.