Customer Profile
Tier-1 automotive wire harness supplier. Product portfolio covers new-energy high-voltage harnesses, charging-gun assemblies, battery-pack wiring and ICE-vehicle low-voltage harnesses. Products supply multiple vehicle OEMs and are exported in volume to Europe.
Project Goals
Reduce labor dependency and stabilize automotive-grade yield
Cut heavy waste loss during injection and extrusion
Consolidate fragmented multi-vendor sourcing
Pass overseas factory audits and carbon-footprint assessments
01 · Project Overview
A Tier-1 Harness Supplier Going Global
02 · Business Challenges
Four Pain Points Holding Back the Plant
03 · KexLink Solution
Five Integrated Modules, One Delivery
Automotive-Grade Precision Conductive Hardware
Pain Point
Limited off-the-shelf hardware specs, long custom-mold lead time. Third-party hardware poorly fits stamping machines, causing crimp offset and insufficient pull-out force. VDE-certified parts for European orders were hard to source.
KexLink Solution
High-purity brass solid/hollow pins, integrated insert housings and bridge terminals. Leveraged 2000+ existing molds to shorten lead time. Hollow-pin design enables harness weight reduction. VDE-certified plug components meet European salt-spray and temperature tests, engineered for perfect compatibility with our stamping machines.
Full-Process Intelligent Automation Equipment
Pain Point
Manual processing damages shielding layers. Unstable crimp pull-force. No QR-code traceability. Paper-based records cannot support IATF 16949 audits. Slow mold changeover for charging-gun overmolding caused long downtime.
KexLink Solution
Full set of self-developed automation lines. Cable-processing units handle large cross-section high-voltage cables without shielding damage — one machine replaces 35 operators. Servo labelers enable QR-code traceability. Testers run continuity, insulation and hipot tests with archivable digital reports. Vertical, C-frame and double-slide injection machines connect to recycling units for closed-loop workflow.
In-Line Hot-Grinding & Pelletizing Closed-Loop System
Pain Point High logistics cost for off-site plastic scrap disposal. Outsourced recycled material fails automotive-grade requirements. Dust & odor from open grinding cannot pass overseas audits.
KexLink Solution On-site inline hot grinding & pelletizing recycles sprues and cable trims into usable pellets, with >95% recovery rate. Fully sealed design controls dust and odor, compliant with EU REACH and OEM green factory standards. 24/7 continuous operation supported.
Eco-Friendly Compounds for Automotive Harnesses
Pain Point Harsh operating environments for automotive wiring harnesses. Expensive imported materials with long lead times. Poor compatibility of third-party plastics causes precipitation and high defect rates. Export products need both RoHS and REACH compliance.
KexLink Solution Halogen-free TPU, TPE, EPDM & cross-linked polyolefin compounds for automotive cables. Custom grades for new-energy high-voltage harnesses and interior signal wires. All materials comply with RoHS & REACH, optimized for KexLink extrusion/injection machines. Recycled pellet blending lowers cost while retaining quality.
Injection Molding Machine & Auxiliary Equipment
Pain Point
Automotive plastics demand strict control over drying, mold temperature and cooling. Insufficient drying causes bubbles; temperature fluctuation brings dimensional drift. Conventional auxiliaries lack overload protection and tend to break down. Manual feeding is labor-intensive.
KexLink Solution
Vertical / double-slide injection machines paired with hopper dryers, autoloaders, mold-temperature controllers, industrial chillers and central feeding systems. Precise PID temperature control manages drying, mold temperature and cooling water. Multi-layer overload protection guarantees long-hour continuous operation. Optimized for automotive plastic molding conditions, reducing defects from bubbles, deformation and dimensional deviation.
04 · KexLink Solution Deployment
Results After Commissioning
Labor & Quality
Manpower dropped significantly. Yield of high-voltage harnesses and charging-gun assemblies improved. Digital test records cleared IATF 16949 audits and overseas factory inspections.
Material Cost
On-site closed-loop recycling cut virgin plastic purchase volume and almost eliminated waste-disposal expenses. Equipment investment achieved expected payback period.
Simplified Supply Chain
Hardware, automation, recycling systems, compounds and auxiliaries delivered and supported by KexLink as a single source — drastically lowering multi-vendor coordination overhead.
Export Compliance
Eco-friendly materials plus enclosed recycling satisfy REACH, RoHS and carbon-footprint requirements. The customer secured more European new-energy harness orders.
“Previously we had to engage multiple vendors for harness-plant upgrading with heavy coordination workload. KexLink delivers hardware, machinery, recycling systems and plastic compounds as a full package with well-coordinated commissioning. They helped us stabilize automotive-grade yield while real-world plastic-waste recycling reduced production cost. Our European-project environmental audit requirements are fully satisfied. KexLink is our trusted one-stop supporting partner.”