Recreational Vehicles
Restoring 1,000 vehicles in 3 weeks through rapid engineering response.
Background
Rising Demand for Custom Cooling Harnesses
A global data center cooling OEM specializing in liquid cooling and thermal management systems experienced a surge in demand driven by AI workloads. Within a three-month period, ECI received 3–5x higher wire harness orders to support liquid-cooled rack systems.
The increase exposed a production constraint: manual strip and crimp processes could not support the required volumes, putting throughput and lead times at risk.
The customer needed a fast, scalable way to increase capacity without compromising quality.
Our Approach
Automating the Strip and Crimp Bottleneck
ECI focused on removing the primary production constraints while preserving quality and delivery speed:
- Identified manual strip and crimp operations as the primary bottleneck limiting throughput and consistency.
- Transitioned to automated strip and crimp processing to increase speed and capacity.
- Partnered with equipment suppliers to deploy automation quickly and reliably.
- Integrated in-line quality monitoring to reduce variation and scrap.
Breakthrough Impact
Higher Throughput, Lower Risk,
Shorter Lead Times
The automated process delivered immediate and measurable performance gains:
10-15x Faster
10-15x faster processing with automation compared to hand strip/crimp
Enhanced Reliability
Driving enhanced reliability and quality through consistent, uniform crimps
Shorter Leads
Shorter lead times for large, high-mix harness builds in liquid-cooled rack applications
Improved Ergonomics
Improved ergonomics, eliminating the primary source of repetitive stress from manual crimping
Faster Cycles
Faster cycle times driven by reduced handling and fewer manual transfers
Why ECI Won
Rapid Execution Through Engineering & Manufacturing
ECI delivered a scalable solution aligned to the customer’s accelerated growth:
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Fast, cross-functional execution to remove production bottlenecks quickly
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Rapid automation deployment to meet a 3-5x demand increase
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Strong equipment sourcing capability to scale throughput reliably
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Scalable, customer-focused approach balancing speed, quality, and growth