Wire Harness, Cable & Electromechanical Assembly worked example

Connector Insertion Force at 65% insertion station uptime: a worked example

This worked example runs the connector insertion force numbers for a tougher week than the baseline: 65% insertion station uptime instead of the typical 90%. Estimate connector insertion force for wire harness, cable and electromechanical assembly using production-ready inputs so teams can confirm whether capacity can cover demand before committing the schedule.

The inputs for this scenario

  • Connectors seated per press cycle: 4 units / cycle (held at the documented default)
  • Available press cycles in the window: 480 cycles (held at the documented default)
  • Insertion station uptime: 65 % (the input this scenario stresses; the baseline uses 90)
  • First-pass seating yield: 97 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross connector insertion force capacity = connector insertion force output per cycle × available connector insertion force cycles.
  • Good connector insertion force capacity works out to 1,211 units at these inputs, and this is the headline figure for the scenario.
  • Gross connector insertion force capacity works out to 1,920 units at these inputs.
  • Connector insertion force downtime loss works out to 672 units at these inputs.
  • Connector insertion force yield loss works out to 37.44 units at these inputs.

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 27.78% below the baseline at 1,211 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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Good connector insertion force capacity: 1,211 units (headline result)
  • Gross connector insertion force capacity: 1,920 units
  • Connector insertion force downtime loss: 672 units
  • Connector insertion force yield loss: 37.44 units

Run it with your numbers

  • To rerun this with your own numbers, open the live Connector Insertion Force calculator, set insertion station uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.