Wire Harness, Cable & Electromechanical Assembly worked example

Connector Insertion Force at 99% insertion station uptime: a worked example

This scenario runs the connector insertion force calculation on the strong side: 99% insertion station uptime, with every other input held at its documented default. Use it when connector insertion force in wire harness, cable and electromechanical assembly is being asked to take on more work and you need to know if there is room.

The inputs for this scenario

  • Connectors seated per press cycle: 4 units / cycle (unchanged)
  • Available press cycles in the window: 480 cycles (unchanged)
  • Insertion station uptime: 99 % (raised for this scenario; the documented default is 90)
  • First-pass seating yield: 97 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross connector insertion force capacity = connector insertion force output per cycle × available connector insertion force cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,844 units for good connector insertion force capacity, the number this scenario is built around.
  • At this operating point the engine returns 1,920 units for gross connector insertion force capacity.
  • At this operating point the engine returns 19.2 units for connector insertion force downtime loss.
  • At this operating point the engine returns 57.02 units for connector insertion force yield loss.

How this compares with the baseline

  • Against the tool's baseline example, where insertion station uptime sits at 90% and the headline result is 1,676 units, this scenario comes in 10% above the baseline at 1,844 units.
  • Use it when sizing an insertion cell, quoting takt for a harness program, or quantifying how much throughput a seating-yield problem is costing. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good connector insertion force capacity: 1,844 units (headline result)
  • Gross connector insertion force capacity: 1,920 units
  • Connector insertion force downtime loss: 19.2 units
  • Connector insertion force yield loss: 57.02 units

Run it with your numbers

  • Every input above is editable in the live Connector Insertion Force calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.