Customer Success Story: Automotive Wire Harness Supplier Accelerates Pin Terminal Production with JunSheng HR-PY05E
Customer Profile
A mid-sized automotive wire harness manufacturer based in Southeast Asia, supplying wiring assemblies to Tier-1 automotive parts makers. The company specializes in pin terminal and needle terminal harnesses for engine control modules, sensor wiring, and dashboard electronics. With growing orders from European and Japanese automakers, the factory faced mounting pressure to increase throughput while maintaining stringent quality standards.
The Challenge
Before adopting the JunSheng HR-PY05E, the customer relied on semi-automatic crimping stations that required manual wire feeding and alignment. Key pain points included:
| Challenge |
Impact |
| Inconsistent pin terminal insertion depth |
High defect rate (8-12%), frequent rework |
| Manual wire feeding bottleneck |
Limited to ~2,000 pcs/day per operator |
| Frequent machine changeover for different AWG sizes |
40+ minutes downtime per changeover |
| Labor-intensive quality inspection |
3 dedicated QC staff per shift |
The Solution: JunSheng HR-PY05E
After evaluating multiple suppliers, the customer selected the JunSheng HR-PY05E Automatic Wire Crimping Machine, specifically configured for pin terminal and needle terminal applications. The decision was driven by the machine's unique combination of precision servo control and wide wire compatibility.
Key machine specifications deployed:
- 5 Servo Motors with Drives ensuring synchronized movements for cutting, stripping, twisting, tinning, and terminal insertion
- Wire Range: 16AWG - 32AWG, covering all customer harness specifications on a single platform
- Cutting Length: 35mm - 1,000mm, accommodating both short jumper wires and longer harness segments
- Stripping & Twisting: Front stripping 1-9mm, rear stripping 1-12mm, twisting 3-12mm - precisely matched to pin terminal requirements
- Tinning Capability: 1-12mm integrated tinning for pre-soldered terminal preparation
Premium component configuration:
| Component |
Supplier |
Benefit |
| Linear Guides |
HIWIN (Taiwan) |
Smooth, accurate linear motion with minimal wear |
| Cylinders |
Airtac (Taiwan) |
Reliable pneumatic operation, long service life |
| Ball Screws |
TBI Motion (Taiwan) |
High positioning accuracy for consistent crimping |
| Touch Screen |
We-con High-Definition LCD |
Intuitive parameter setting and real-time monitoring |
Results & Impact
Within three months of deployment, the customer reported measurable improvements across all production KPIs:
| Metric |
Before HR-PY05E |
After HR-PY05E |
| Daily Output (per shift) |
~2,000 pcs |
~5,000 pcs/hour (40,000/shift) |
| Defect Rate |
8-12% |
Below 2% |
| Changeover Time |
40+ minutes |
Under 10 minutes |
| QC Staff Required |
3 per shift |
1 per shift (spot check only) |
| Labor Cost Reduction |
- |
60% per production line |
Customer Feedback
The production manager noted: "The HR-PY05E transformed our pin terminal line. We now run 24/7 with consistent quality - the 5-servo synchronization eliminates the alignment issues we struggled with for years. The machine paid for itself in under 4 months through labor savings alone."
This case demonstrates how JunSheng's precision-engineered crimping solutions empower wire harness manufacturers to meet growing automotive industry demands while improving profitability and product quality.
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