Wire Harness, Cable & Electromechanical Assembly worked example

Harness Automation Payback with crimp and cut-strip cell capital cost of 62,500 $: a worked example

This scenario runs the harness automation payback calculation on the strong side: crimp and cut-strip cell capital cost of 62,500 $, with every other input held at its documented default. Use it when harness automation payback in wire harness, cable and electromechanical assembly is being compared against another wire harness, cable and electromechanical assembly project for the same budget.

The inputs for this scenario

  • Crimp/cut-strip cell capital cost: 62,500 $ (raised for this scenario; the documented default is 25,000)
  • Annual labor and scrap savings vs. hand assembly: 18,000 $ / yr (unchanged)
  • Annual maintenance, tooling and operator cost: 2,500 $ / yr (unchanged)

Working through the calculation

  • Applying the documented formula (Net annual harness automation payback savings = annual harness automation payback savings - annual harness automation payback support cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 4.03 yr for harness automation payback payback period, the number this scenario is built around.
  • At this operating point the engine returns 15,500 $ / yr for net annual harness automation payback savings.
  • At this operating point the engine returns 62,500 $ for harness automation payback investment.
  • At this operating point the engine returns 15,000 $ for five-year net harness automation payback value.

How this compares with the baseline

  • Against the tool's baseline example, where crimp and cut-strip cell capital cost sits at 25,000 $ and the headline result is 1.61 yr, this scenario comes in 150% above the baseline at 4.03 yr.
  • Use it when comparing an automated cut-strip-crimp or crimp cell against hand assembly, or when a supplier quotes an automation line and you need to test the ROI claim. 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

  • Harness automation payback payback period: 4.03 yr (headline result)
  • Net annual harness automation payback savings: 15,500 $ / yr
  • Harness automation payback investment: 62,500 $
  • Five-year net harness automation payback value: 15,000 $

Run it with your numbers

  • Every input above is editable in the live Harness Automation Payback calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.