EV Battery Harness: 60% Cost Reduction
How we helped a European Tier-1 supplier transform their EV harness supply chain, cutting costs by 60% while improving quality and reducing lead times by half.
Client
Global Automotive Tier-1 Supplier
European EV manufacturing partner
Industry
Automotive / EV
High-voltage battery systems
Products
Battery Harnesses
400V+ high-voltage cables
The Challenge
A leading European Tier-1 automotive supplier was facing critical supply chain challenges with their EV battery harness program. Their existing European suppliers were quoting 16-week lead times and €45 per unit costs - making their EV programs commercially unviable against Asian competitors.
Key Pain Points:
- 116-week lead times causing production schedule delays
- 2€45/unit cost making EV programs unprofitable
- 3Multiple suppliers creating quality inconsistencies
- 4No flexibility for design changes during ramp-up
Requirements:
- IATF 16949 certification mandatory
- 400V+ high-voltage capability
- 100% electrical testing on every unit
- Scalability to 50,000+ units/month
Our Solution
We implemented a comprehensive solution that addressed every pain point while exceeding quality requirements.
Design for Manufacturability (DFM) Optimization
Our engineering team analyzed the original design and identified opportunities to reduce assembly time by 40%. We consolidated wire routing, optimized connector placement, and standardized components without compromising electrical performance.
Single-Source Manufacturing
We consolidated 3 separate suppliers into our single IATF 16949 certified facility, eliminating coordination delays and quality variations. Dedicated production lines ensure consistent output and rapid response to volume changes.
100% Electrical Testing
Every single harness undergoes comprehensive high-voltage testing, continuity verification, and insulation resistance testing. Automated test systems ensure zero defects escape to the customer's production line.
Dual-Factory Supply Security
Production capability established in both China and Philippines facilities, providing backup capacity and tariff optimization options. The client now has complete supply chain redundancy for critical EV components.
The Results
"Their engineering team redesigned our harness to reduce assembly time by 40% without compromising quality. The dual-factory strategy gives us supply chain confidence we never had before. This partnership has been transformational for our EV program competitiveness.
Technical Specifications
| Voltage Rating | 400V - 800V DC |
| Wire Gauge | AWG 2 - AWG 8 (High-voltage sections) |
| Shielding | 360° braided shield with drain wire |
| Jacket Material | Orange XLPE (cross-linked polyethylene) |
| Operating Temperature | -40°C to +125°C |
| Certifications | IATF 16949, USCAR compliant |
| Testing | 100% Hi-Pot, continuity, insulation resistance |
Facing Similar Challenges?
Get a competitive quote for your EV harness project. Our engineering team is ready to optimize your design for cost and quality.