Zero-Failure Crimping for Wire Harness Manufacturing
Industries
Automotive Wire Harness
EV Harness Systems
OEM Production Lines
Application Criticality: HIGH
The Challenge
- Variation in crimp quality due to operator skill
- Tool wear not detected early
- Rejections during OEM audits
- Inconsistent pull-out force across batches
Why It Matters
A poor crimp may pass visual inspection but fail under:
- Vibration
- Heat cycling
- Long-term current load
This leads to field failures and warranty risk.
How Rennsteig Solves This
- Precisely controlled crimp force
- Uniform crimp geometry across operators
- High repeatability batch after batch
- Long tool life with predictable wear
Result
- Reduced rework & scrap
- Audit-friendly crimping process
- Consistent electrical & mechanical performance
Typical Tool Kit Value: ₹5–12 Lakhs per harness line
Recommended Production Toolkit
636 084 3
Crimping machine CM 25-3
8782 0009 6
4/8-Indent Crimping Tool SelectorCrimp HDT-48
8000 1001 3
Miniature wire cutter and strand trimming tool
700 020 36
Cable shears D20
700 027 2
Cable shears D27
700 038 3
Cable shears D38
712 060 3
Cable cutter D60
STILO60
Battery operated hydraulic crimping tool | 60 kN | max. 300 mm2
AP130-C2
Battery Operated Hydraulic Crimping Tool up to 130kN
PMC25
Mechanical Crimpingtool x cable lugs 10-25mm² hex. Crimp
95 32 320
Cable Cutter (ratchet principle, 3-stage)
12 52 195
KNIPEX PreciStrip16® Automatic insulation stripper
Torque Screwdriver
Wera – Torque Controlled Fastening
VDE screwdrivers
Wera
Click Torque A 6 Set Adjustable Torque Wrench
Wera
