Custom Wiring Harness

Specifications

The primary objective of POPULAR SYSTEMS is to manufacture high quality Assembly wiring harnesses. The main agenda of the company since inception has been to provide its customers with world class products at competitive prices and fortify consumer trust.

Infrastructure

Manufacturing/Focused Factory

Our commitment to the Focused Factory (Synchronous Manufacturing) concept has allowed us to streamline manufacturing in many ways, including better workflow, improved material handling, reduced inventory and better utilization of floor space.

• Our diverse manufacturing capabilities include discrete wiring, panel assemblies, and molded connectors. We are capable of providing prototypes of low- to high- volume production of simple to complex harnesses. We provide 100% electrical testing on all assemblies. Our "full-service" capabilities can be tailored specifically to you, our customer.
• Our design team is ready to provide you with innovative solutions to your most demanding requirements. We are dedicated to the integrity of your total design and understand your needs for integrated functionality, part consolidation, and system reliability. We have the engineering and mechanical resources to respond quickly to new product requirements and make in-house engineering changes.

Our commitment to Total Quality Management is supported by strategic planning, process analysis and implementation. From the moment your order is received, a cross-functional team is dedicated to your needs from product definition, through launch and on to program assessment where we identify opportunities for continuous improvement

MACHINERIES

Fully Automatic Wire Cutting striping and crimping machine – 1 no

Wire cutting and stripping machine – 4 no      

Multi core cable Cutting and de-sheathing machine – 1 no

Pneumatic core stripper – 2 nos

Wire cutting stripping and twisting machine – 1 no

Microprocessor based Battery cable Cutting Machine – 1 no

Pneumatic Cable outer jacket removal machine – 1 no    

Pneumatic Crimping machine for Scattered terminals–5 nos              

Semi automatic crimping machines – 10 nos

Electronic Crimping Presses – 15 nos

Applicators – 25 nos

Toggle crimping machines – 30 nos

Wire stripping and twisting machines - 5 nos

Soldering station – 10 nos

Coupler assembly station – 3 nos

Air Compressor ( 3 Hp and 5 Hp) – 1 no each

25 KVA Generator – 1 no
Microprocessor based Harness tester- 2 nos
(1024 POINTS AND 64 POINTS)

 

MANPOWER

Total No. Of Employees:50

 

Quality

We are an ISO 9001:2008 firm.

POPULAR SYSTEMS invests heavily on testing procedures and protocols to ensure trouble free, reliable outputs. We have a mating inspection section, coupler seating position-inspection section and harness tester to ensure high quality delivery.

SYSTEMS IMPLEMENTED

• Statistical Quality Control           -           SQC
• 5 Systems                                   -           5’S
• Total Productivity Management    -           TPM
• 5 Why Analysis
• Shop Floor Control

Product Information

 Raw Materials Used For Production:

We use Lapp (Single/Multi core) cables, armored cables, Shielded cables and also PVC wires for manufacture of our harnesses.

We use imported connectors such as Sumitomo, Tyco, Berg and Molex for specific applications of our customers. We also have good tie-ups with best manufacturers of couplers and terminals in India.

Polyamides and Master batches from SRF and DUPONT.

We make assembly wiring Harness for the Speedometers, Tank Units and Electrical Gauges. We make harnesses for Elevators, Metering pumps, Programmed doors,Textile machines, Mold machine controllers etc..

 Production Capacity
 
We make around Five million crimps per month and we have ambitious expansion plans to make around Ten million crimps per month .

 Strengths                          

1. JIT Assembly Line

2. Single Piece Flow Manufacturing System

3. Employee Involvement at all levels

4. Flexible Production Planning System

5. Un-paralleled Customer Service

6. Good Business Practices and Good Manufacturing Practices at all

Levels

7. Complete Transparency with our customers

 

COMPETITIVENES…

 

We maintain competitiveness with the following steps

 

 •Procurement of Raw Materials from the most cost effective sources, 

•Keeping the Least Inventory. 

•Adoption of the best process to increase Productivity to the optimum level. 

•Adoption of the latest Techniques, 

•Value Engineering as a Continuous Process 

•Keeping the Overheads to the Essentials with Minimum level 

•Best utilization of Machinery, Man Power, Space, Power, etc., to gain the maximum efficiency. 

•Best Quality product with competitive price. 

•100% acceptance with customers (Zero defects)

 

All the products manufactured cater to the specific requirements of the clients. We manufacture products according to the International Standards. Our performance and commitment are the key for our success. We make sure that people's roles are clear and that they are held accountable for their actions and believe in absolute honesty and transparency in our dealings with our clients and business associates.