Automated Wire & Cable Assemblies

Stylized black and white wire harness graphic showcasing Kato Cable’s advanced cable design
A wire harness board.

Automated Services Built for Speed, Accuracy & Scale

Kato Cable delivers automated wire harness and cable assembly services designed for speed, accuracy, and consistency. Our automation technology supports high-mix, high-volume production with repeatable results that meet exact specifications.


From cutting and stripping to crimping and connector insertion, each step is completed using advanced equipment to reduce cycle times and improve connection quality. This approach minimizes manual variation, shortens lead times, and ensures every assembly is built to perform reliably in the field.

Our Automated Manufacturing Capabilities

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Automated Wire Cutting & Stripping

Machines that precisely cut and strip wires to required lengths, minimizing human error and increasing production speed.

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Automated Testing Systems

Machines that run various tests (electrical, mechanical, etc.) on cable assemblies to verify they meet the required specifications and performance standards.

Cable connector and coiled cable icon

Automated Cable Assembly Machines

Systems designed to automatically assemble wires into cables with consistent quality, reducing manual labor and improving throughput.

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End-to-End Manufacturing Software Solutions

Enterprise Resource Planning (ERP) systems that integrate design, production, inventory, and distribution for streamlined workflow and better production planning.

Why OEMs Love Automated Wire Harnesses & Cable Assemblies

Automated assembly brings structure and efficiency to high-volume wire harness production. At Kato Cable, our automation platforms are engineered to support tight tolerances, reduce cycle times, and deliver repeatable performance across every order.



Key benefits include:

  • Faster Production Cycles: Automated systems accelerate throughput and support large-scale builds with consistent speed.
  • Reliable Output: Configurable equipment maintains uniformity in crimps, terminations, and routing.
  • Fewer Manual Steps: Minimizing hand assembly reduces variation and streamlines process flow.
  • Lower Error Rates: Built-in safeguards and process control features help catch issues early and limit rework.
  • Adaptable Capabilities: Our systems support a wide range of wire gauges, insulation types, and layout complexities.
A man wearing headphones is working in a factory.
Black and white wire harness design element representing Kato Cable’s precision connectivity
Two female Kato Cable technicians inspecting a wiring board.

Process Control & Engineering Control Services

Process Control

Precision and consistency are at the heart of every custom cable solution. Our Process Control strategies ensure each assembly meets exact specifications, from initial concept to final production. Through rigorous quality checks, standardized procedures, and real-time monitoring, we optimize efficiency while maintaining the highest level of reliability.

Engineering Control

From concept to completion, Engineering Control ensures every design is optimized for functionality, manufacturability, and long-term performance.  Our expert team evaluates form, fit, and function, applies industry best practices and testing protocols, and leverages innovative solutions to deliver high-quality and cost-effective cable and harness assemblies.

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Our Products are Proudly Made in the USA

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Industries That Utilize Our Automated Assemblies

Our automated wire harness assembly services support OEMs in industries where consistent performance, scalability, and production speed are essential. We work closely with manufacturers who require reliable connectivity solutions for complex systems and demanding operating conditions.


Industries we serve include:

Commercial Vehicles: Harness assemblies for EV platforms, commercial vehicles, and specialty builds.
Industrial Equipment: Solutions for control systems, factory automation, and heavy machinery.
Medical Devices: Clean, consistent builds for patient monitoring, diagnostics, and surgical equipment.
Power Generation: Assemblies designed to meet high-load electrical and environmental requirements.
Powersports & Recreational Vehicles: Compact and durable wiring for ATVs, UTVs, snowmobiles, and marine applications.
Agricultural Equipment: Rugged harnesses designed for vibration, moisture, and temperature extremes in field environments.

The Kato Cable Advantage

The Kato Cable Advantage is a holistic approach to looking at the value that you bring to your customers, employees and community. Our customers relate directly to our responsiveness and engineering value, to the investments that we have made into efficiencies and automation, and to the key metrics of industry leading Quality and On Time Delivery. Our employees relate to a sense of inclusion, an appreciation and value to feedback, and the philosophy of making improvements every day. Our community relates to our growth and volunteerism and leadership that we strive for in our region. Together these attributes and values truly deliver the Kato Cable Advantage!

Quality & Reliability

Delivering precision-engineered wire harnesses, cable assemblies, and electro-mechanical assemblies that meet the highest industry standards.

Innovation

Continuously improving processes and technologies to provide cutting-edge solutions for diverse industries.

Customer Commitment

Building strong partnerships through collaboration, responsiveness, and tailored solutions.

Our Certifications

DQS quality management logo.
WHMA-A-620 logo.
cURus UL-Approved logo

Automation FAQs

  • What are the main benefits of your automated assembly lines?

    Our automated systems drastically reduce lead times, optimize material usage, and practically eliminate human error. This allows us to scale production efficiently while maintaining strict, uniform quality across high-volume OEM orders.

  • How does automation improve quality control during production?

    We integrate real-time quality monitoring directly into our automated lines. Features like dynamic crimp force monitoring analyze every single termination in milliseconds, instantly flagging and sorting out any defects before they can proceed down the line.

  • Can your automated systems handle high-mix, low-volume orders?

    While automation excels at high-volume runs, our modern machinery features quick-change tooling and programmable setups. This allows us to rapidly pivot between different assemblies, offering flexibility for high-mix production needs.

  • What automated capabilities do you use for wire preparation?

    We utilize advanced, high-speed automated systems for simultaneous cutting, stripping, multi-wire twisting, and terminal crimping. This ensures millimeter-precise accuracy and rock-solid repeatability on millions of components.

  • How does Kato Cable blend automation with manual craftsmanship?

    We take a hybrid approach. We use automation for high-speed, highly repetitive tasks—like cutting and crimping—and rely on our IPC-certified technicians for complex routing, custom box builds, and final quality inspections.

Stay Connected with our Blog

Hands installing a green RAM stick into a computer motherboard.

Control Panel vs. Wire Harness vs. Cable Assembly: OEM Guide

By Kato Cable • July 2, 2026
Wire harness vs cable assembly vs control panel: learn key differences, applications, costs, and how OEMs choose the right interconnect solution.
Close-up of a bundle of multi-colored electrical wires connected to several white plastic electrical connectors.

How to Select the Right Type of Wire Harness Connector

March 30, 2026
Learn common wire harness connector types, key selection factors, and OEM applications to choose the right connector for reliable electrical systems.
Colorful electrical wires hanging on metal hooks.

Optimizing Wire Harness Design for Harsh Environments

January 19, 2026
Explore how wire harness design withstands harsh environments. Learn key design principles, material choices, and testing methods for lasting performance.
Stylized black and white wire harness graphic showcasing Kato Cable’s advanced cable design

Automation Contact Us

Looking for Support?

Ready to optimize your wire harness production with automation? Kato Cable is here to help. Our experienced team can guide you through every stage of the process, from design consultation to high-volume manufacturing.

Let’s connect.


Request a Quote or follow us on LinkedIn and Facebook to explore how our automated wire harness assembly services can support your next project.