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Don Nelson, Senior Vice President of Operations at PRIDE Industries, was interviewed recently by Electronics Manufacturing News. In Part Two of the two-part interview, Don gives valuable advice for reshoring manufacturing successfully. Not sure whether or not your company should reshore operations? See Part One of the interview.

To keep up with industry news and trends, subscribe to Electronics Manufacturing News.

Electronics Manufacturing News (EMN)
What are some strategies for reshoring manufacturing?

Reshoring manufacturing operations back to the U.S. requires a multi-faceted strategy that addresses logistics, weather, labor, and warehouse operations.

Don Nelson
First, you need a plan, one that has input and buy-in from all the relevant stakeholders, including engineers, supply chain managers, and execs. Then, if the feasibility studies and risk assessments yield a green light, you can start slowly.

For most companies, it makes sense to take a phased approach. Like a hybrid model, where you start by reshoring IP-sensitive or high-value production first and then expand the products you make domestically as your production capabilities increase.

Similarly, depending on why you’re choosing to reshore, you may not need to come all the way back to the U.S. You can solve a lot of shipping and weather problems by nearshoring to a place like Mexico. Of course, even with nearshoring, you still have the issue of tariffs.

If you bring production back to the U.S., then I recommend investing in cutting-edge automation. That will help reduce labor costs, and can also improve quality and efficiency over what you had before. Reshoring manufacturing gives you a clean slate; I’d make the most of it by setting up state-of-the-art systems.

And finally—and this is actually something I’d do at the planning stage—make sure you investigate grants, tax breaks, and other government incentives for bringing your manufacturing back onshore. Federal, state, and even local governments sometimes offer these economic incentives, and the terms usually aren’t onerous, which makes these incentives a good deal. Never leave money sitting on the table.

EMN
When does it make sense to use a contract manufacturer as a way to reshore? How do you determine when to do it yourself and when to rely on a third party?

Don
There are certain situations where a lot of risk can be avoided by using a contract manufacturer. Companies that have variable production volumes, for example, can get a lot of benefit from this kind of partnership, because contract manufacturers are equipped to efficiently manage fluctuations in demand—whether it’s ramping up a new product or scaling down during a slow period.

Contract manufacturers also bring deep expertise in regulatory compliance, and can help their partners navigate local and international standards like UL, FCC, or RoHS. This expertise is crucial for avoiding legal pitfalls and ensuring a smooth market entry.

Another advantage companies get in this type of partnership is the ability to leverage their contract manufacturer’s infrastructure and supply chain relationships, which can significantly speed up the time to market for new products. This is especially valuable in the fast-paced electronics sector, where being first to market can be a major competitive advantage and a real incentive for reshoring manufacturing in the first place.

EMN
What strategies would you recommend for companies to ensure a smooth and cost-effective transition when reshoring manufacturing operations back to the U.S.?

Don
Reshoring manufacturing back to the U.S. requires a multi-faceted strategy that addresses logistics, weather, labor, warehouse operations, and robust management systems.

Start with thorough logistics planning. Given tariff policy shifts and changing trade routes—including potential disruptions around key passageways like the Panama Canal—evaluate alternate distribution methods and secure partnerships with logistics specialists who understand U.S. regulations and geography. Integrate advanced logistics management (LM) systems and IoT-enabled platforms to optimize supply chain routes, predict delays, and maintain real-time visibility into goods movement.

Weather remains a critical factor: U.S. regions face diverse climates, and manufacturing hubs in the Southeast or Midwest may encounter hurricanes, storms, or winter delays. Use predictive analytics within LM systems to build contingency plans around severe weather, including dynamic rerouting and warehouse stock adjustments.

Also, be sure to assess labor market conditions by focusing on strategic recruitment, workforce training in automation, and upskilling existing employees to collaborate with robotics and AI-driven equipment. Persistent labor shortages demand creative workforce solutions, like investing in competitive compensation packages and automation to offset gaps.

Warehouses should be re-evaluated for scalability, flexibility, and sustainability. Implementation of advanced warehouse management systems (WMS) supports inventory controls, lean operations, and rapid order fulfillment. Consider green building standards and energy-efficient upgrades to minimize overhead costs in new facilities; this also helps companies future-proof against energy price shocks and respond to demands for sustainable operations.

Finally, integrate a comprehensive quality management system (QMS) to drive consistency and compliance from day one. A well-documented QMS ensures process control, traceability, real-time quality monitoring, and rapid problem resolution—all of which are crucial during the turbulence of relocation and startup. By combining tech-enabled management systems, strategic workforce planning, climate-aware logistics, and agile warehousing, companies can significantly mitigate risks, streamline costs, and position themselves for sustainable growth in the reshored U.S. manufacturing landscape.

EMN
How important is having a trained workforce for successfully reshoring manufacturing, and what steps should companies take to build and retain a skilled workforce?

Don
A trained workforce is absolutely critical to the success of reshoring in electronics manufacturing. While bringing production back to domestic soil involves investments in facilities and technology, the human element remains the backbone of sustainable operations. A skilled workforce not only ensures smooth production processes but also drives the innovation and operational efficiency that’s essential for competitiveness.

To build and retain this workforce, companies should start with comprehensive training programs. Deploying structured training, including continuous improvement methodologies like Six Sigma and Kaizen, sharpens process quality and problem-solving skills. And partnerships with trade schools, community colleges, and technical institutions can foster talent pipelines and keep operations resilient. These collaborations also help fast-track apprenticeships and certifications tailored to modern manufacturing technologies. Finally, as a leader of a social enterprise with a mission to provide jobs for people with disabilities, I also recommend that companies look beyond their traditional hiring pools to include overlooked groups like people with disabilities and military veterans.

Beyond initial training, continuous employee development is essential. Leveraging modern training technologies like VR simulations and e-learning platforms enhances workforce readiness for complex manufacturing environments. Companies should also foster a culture of innovation and learning, and offer growth opportunities that boost retention.

Investing in competitive compensation, wellness programs, and flexible work arrangements also plays a crucial role in attracting and keeping skilled workers. Strong workforce development efforts reduce turnover and enhance safety, which are significant operational advantages.

Ultimately, successful reshoring requires a strategic emphasis on workforce capabilities. That means building and nurturing a skilled, motivated team backed by institutional partnerships, ongoing training, and continuous talent pipeline development. This approach not only bridges the critical skills gap but also ensures that reshored operations are efficient, innovative, and competitive.

EMN
What role does investing in advanced technologies, such as automation or AI, play in making reshoring both viable and competitive?

Don Nelson
Don Nelson, Senior Vice President of Operations, PRIDE Industries

Don
Investing in automation and AI are crucial for reshoring manufacturing successfully. Reshoring can sometimes bring higher labor costs compared to offshoring, so for reshoring to make sense, it must make companies more agile and efficient. Automation helps by taking over repetitive, dangerous, or precision-based tasks, boosting productivity and reducing labor costs. AI enhances automation by enabling smarter, adaptive systems, like AI-driven collaborative robots (cobots) that work safely alongside humans to improve speed, quality, and flexibility on production lines.

AI is particularly valuable for benchmarking and forecasting. By analyzing real-time production data and market trends, AI systems create digital twins that enable manufacturers to simulate and optimize operations before implementing changes. This supports better demand forecasting, inventory management, and resource allocation, which reduces waste and downtime. However, for AI to be truly effective, you have to ask the right questions and define relevant objectives. Without clear direction, AI’s predictive and analytical capabilities can be underutilized or misapplied.

Together, AI and automation form a powerful combination. Automation executes physical tasks efficiently; AI continuously learns from data to optimize processes, predict maintenance needs, and adapt workflows dynamically. This synergy allows reshored manufacturing operations to achieve the flexibility, quality, and cost-effectiveness that companies need to compete globally. And that’s what bridges the gap between higher domestic costs and supply chain resilience. When companies embrace these technologies, then reshoring becomes a true competitive advantage.

EMN
What advice would you give for building strong relationships with domestic suppliers to ensure a resilient and efficient supply chain after reshoring manufacturing?

Don
I think the basis for any good manufacturing partnership is transparency. That means sharing accurate forecasts, production schedules, and potential challenges early. This fosters trust and allows suppliers to plan proactively. Equally important is clear, consistent communication at multiple levels—from strategic leadership meetings to operational check-ins—so issues are addressed before they become disruptions.

Approach the relationship as a partnership, where both sides commit to long-term success rather than short-term transactions. In this model, companies and their suppliers share mutual risk for mutual gain. That’s why I recommend collaborating on product development and inventory management, and even investing jointly in new technology.

A resilient relationship also depends on a willingness to compromise. Lead times, pricing, or minimum order quantities may need adjustment as domestic supply chains scale. Finding balanced solutions ensures both parties remain profitable and competitive.

The fact is, in the most successful partnerships, suppliers are treated as strategic allies, not interchangeable vendors. When you combine transparency with open communication and a shared risk-reward commitment, you get a partnership that can weather market fluctuations, accelerate innovation, and secure your reshoring investment for the long term.

EMN
Could you talk about a specific tactic for building a strong partnership with a domestic supplier?

Don
Sure. I can give you three.

First, make sure you engage suppliers early and regularly in collaborative strategic planning sessions, so you can align goals, expectations, and performance metrics. This includes sharing forecasts, capacity plans, and ideas for reducing costs and improving quality. Jointly setting measurable KPIs and mutual success targets builds shared accountability and trust, which embodies the “mutual risk for mutual gain” philosophy.

Second, establish structured communication channels and meeting cadences—ranging from executive-level relationship reviews to day-to-day operations check-ins. Openness about challenges or potential disruptions encourages problem-solving rather than finger-pointing. This transparency helps you anticipate risks and develop contingency plans together, which strengthens your supply chain.

Third, develop mechanisms for shared investment in process improvements, technology upgrades, or capacity expansions that benefit both you and your supplier. Adopt contract terms that reflect a willingness to compromise on lead times, pricing, or order sizes as market conditions evolve. This encourages a true partnership mindset where both sides balance risk and reward, fostering long-term stability and innovation.

Following these tactics with your supplier lets you transform a transactional relationship into a trusted partnership that supports efficiency, flexibility, and mutual growth.

EMN
When choosing a third-party manufacturing contractor in the U.S., what key factors should executives consider in order to ensure a reliable partnership?

Don
When you’re choosing a manufacturing partner, you really have to look at it from both a strategic and a practical angle. The first thing I tell companies is: Check the contract manufacturer’s track record. How long have they been doing this, and who have they worked with? That tells you a lot about their staying power and reliability.

Just as important is experience in your specific industry. You want a partner who understands your regulatory requirements and the quality standards you’re held to. Any potential partner should be able to show you its certifications, audit history, and the quality systems it has in place.

But technical capability isn’t the whole story. Flexibility is huge. Demand shifts, designs evolve, and supply chain surprises happen. The right contractor can flex with those changes without blowing up your schedule or your budget.

And then there’s cultural fit, which I think is often underestimated. Do they communicate in a way that works for your team? Do they approach problem-solving and accountability the same way you do? That alignment makes a big difference when challenges come up. At the end of the day, the strongest partnerships blend operational excellence with adaptability and a shared way of doing business.

A Reshoring Partner You Can Rely On

At PRIDE Industries, our state-of-the-art facilities minimize your risk of supply chain disruption, optimize manufacturing and fulfillment processing, and provide flexible, on-demand inventory schedules. Partner with us to better manage the unpredictability of tariffs, component availability, and shipping costs—while meeting customer demand for products made in the USA.
Learn More

Don Nelson, Senior Vice President of Operations at PRIDE Industries, was interviewed recently by Electronics Manufacturing News. In Part One of this two-part interview, Don outlines the benefits of reshoring and the impact of tariffs. He also shares which factors to consider when determining whether or not to reshore manufacturing. Already know that your company needs to reshore? Then see Part Two of this interview to get actionable advice for successful reshoring.

To keep up with industry news and trends, subscribe to Electronics Manufacturing News.

Electronics Manufacturing News (EMN)
When does it make sense for a company to reshore?

Don Nelson
Put simply, it depends on the math.

The impact of tariffs has been a lot like COVID’s—they’ve shown just how shaky and unpredictable the global supply chain can be. And just like the pandemic, tariffs aren’t going away.

Part of what’s driving a return to domestic production is the fact that the incentives to offshore are so much less compelling than they were a decade or so ago. Twenty years ago, material and labor costs were markedly lower in some countries than in the U.S., and shipping costs were reasonable. And if you happen to be in an industry where that’s still the case, then maybe you don’t want to change anything.

But for most companies today, the math has changed. All those costs are higher now. And there are new complications—extreme weather, tariffs, and geopolitical uncertainty. In this type of environment, it makes sense for companies that sell a lot to the U.S. to move at least some production here if they can, so that they don’t have all their eggs in one basket.

EMN
What are some costs and risks of reshoring?

Don
Reshoring does have its risks, which is why manufacturers need to plan carefully. If you’re building factories, that’s a big capital investment. It may be simpler to start by using a domestic contract manufacturer, which lets you retain more flexibility, should you decide to offshore at a later date.

Another issue is the cost structure, which can be different domestically than abroad. Labor costs have generally been higher in the U.S. than in typical offshore countries, but that’s changing—foreign wages have been moving up in recent years, so that advantage is eroding.

There’s also the issue of supply chain realignment, finding new sources for materials and components. Here again, you can get around this problem by contracting with a manufacturer that’s already well-established in the U.S., so that you can take advantage of its existing labor and materials ecosystem.

EMN
Regulatory compliance must be easier with domestic facilities, right? And is it easier to control quality?

Don
Not necessarily. Look, there are plenty of good reasons to reshore, but I don’t think compliance is one of them. A product that’s sold in the U.S. has to meet certain standards whether it’s made here or in Vietnam.

It is true that—for some companies—quality control becomes easier when they reshore, if only because it’s a lot less hassle to fly to another state in the U.S. than to get your personnel halfway around the world for a product inspection at a contract manufacturer.

EMN
What are the most significant benefits that companies can reap when they reshore manufacturing, particularly in terms of mitigating the impact of tariffs on their businesses?

Don
I think there are a couple of things to keep in mind when it comes to tariffs. First, the impact of tariffs has been a lot like COVID’s—they’ve shown just how shaky and unpredictable the global supply chain can be. Second, just like the pandemic, tariffs aren’t going away. They’re pretty much the new normal now, popping up all over the world and making it tough to plan ahead.

Bringing production back closer to home lets companies avoid some of those tariff headaches. It also means they’re not as exposed to sudden cost spikes or new trade rules, so pricing is more stable and predictable. Plus, reshoring can give companies a lot more control over operations, which lets them react faster if something unexpected happens—even if that something is positive, like adjusting to unexpectedly high demand.

Another advantage of reshoring is greater control over shipping costs. Bad weather, geopolitical uncertainty, port delays—that can all make shipping expensive and unpredictable. Reshoring pretty much eliminates that headache. The bottom line is that reshoring makes supply chains stronger and more flexible. Keeping production close means companies are better able to ride out the next pandemic, or weather a catastrophe, or cope with a new tariff, or whatever. You’re just on a more solid footing.

Don Nelson
Don Nelson, Senior Vice President of Operations, PRIDE Industries

EMN
Let’s take a deeper dive into logistics. Specifically, how does reshoring help companies reduce logistics and shipping costs, and why is this especially important in a high-tariff environment?

Don
First off, if a company wants to cut shipping and logistics costs, reshoring is one of the most effective moves they can make. Bringing production closer to your main markets saves on the long-haul freight bills—that’s about 20–30% savings on transportation alone. It also avoids the headaches that come with unpredictable shipping schedules, port delays, and customs bottlenecks. In a high-tariff environment, this is even more critical—by manufacturing domestically, you sidestep those hefty import tariffs that can eat into your margins overnight.

Shorter supply chains also mean a company can run leaner on inventory. With faster lead times, you don’t need to tie up as much cash in safety stock or oversized warehouses. Inventory strategies run across a spectrum, from just-in-case to just-in-time. Reshoring lets a company move closer to a just-in-time approach, which lowers warehousing costs and reduces the risk of excess or obsolete inventory.

Another reshoring plus: Domestic facilities can leverage advanced automation and smarter layouts, so you get more out of every square foot of warehouse space. And going back to tariffs—don’t forget about free trade zones. Companies can leverage FTZs to defer or maybe eliminate certain duties on imported components. FTZs are another tool in the toolbox, and these days, companies have to use every tool at their disposal.

EMN
In your experience, how does reshoring improve quality control and compliance with local regulations compared to overseas manufacturing?

Don
I always say that reshoring isn’t just about geography, and that’s especially true when it comes to things like quality and compliance.

When companies decide to reshore their manufacturing, they often see a big boost in quality control and regulatory compliance. Think about it—having production closer to home means you can keep a much closer eye on things. Instead of relying on reports and delayed feedback from overseas factories, you’re right there, able to spot issues early and take corrective actions quickly. That kind of hands-on oversight really cuts down on defects and keeps quality consistent.

Plus, reshoring makes compliance with local regulations way more straightforward. Local teams and subcontractors already know the ins and outs of the regulatory environment—they understand the standards and expectations already—so there’s less guesswork and fewer surprises. And being able to work directly with local subcontractors means that communication is smoother, another thing that helps ensure everyone is on the same page regarding compliance and quality standards.

All of this adds up to a manufacturing process that’s more transparent, agile, and aligned with both quality goals and regulatory demands. So, reshoring isn’t just about geography—it’s a smart move for tighter control and peace of mind.

EMN
For executives considering reshoring, what are the most common pitfalls to avoid, and how can they set their reshoring initiatives up for long-term success?

Don
One of the biggest pitfalls executives face when reshoring is underestimating the true complexity of the transition. It’s not simply a matter of moving production back home; local supply chains, labor availability, and regulatory requirements can look very different from overseas operations. Many companies also overlook hidden costs—like hiring or retraining their current workforce, qualifying new suppliers, or investing in automation. Any of these factors can erode the expected gains if not accounted for early.

Another common misstep is treating reshoring as a one-time tactical project instead of a long-term strategic shift. That mindset often leads to piecemeal investments rather than building a resilient, future-ready operation.

The organizations that succeed are the ones that approach reshoring holistically. They map the full supply chain, model total landed costs, and build strong relationships with domestic suppliers before committing to large-scale moves. They also invest in technology—automation, data analytics, and digitalized operations—to offset higher labor costs and ensure consistent output. Perhaps most importantly, successful companies align their reshoring strategy with broader business goals, whether that’s improving customer responsiveness, strengthening resilience, or accelerating innovation. Reshoring done right isn’t just about geography; it’s about creating a manufacturing system that can scale, adapt, and compete in the long run.

EMN
Is there anything else you’d like to add? Any parting words of advice for electronics manufacturers who want to reshore manufacturing?

Don
Tariffs definitely play a role in reshoring decisions, but if tariff concerns are the main reason you’re thinking of reshoring, think again. Tariffs can create short-term cost pressures and uncertainty, but executives need to think long term. For many companies, it’s hard to justify uprooting global supply chains solely on the possibility of future tariff volatility.

The reality is that there are a lot of other good reasons to reshore. And in my opinion, lead time reduction is at the top of the list—being closer to end customers means faster response to design changes and smoother alignment with just-in-time production models. Supply chain resilience is another factor. The pandemic, port bottlenecks, and geopolitical tensions underscored the vulnerability of overextended supply chains. There’s no question that reshoring is a way to mitigate these risks.

In addition, labor dynamics are shifting. The wage gap between traditionally low-cost regions and North America has narrowed, while automation and advanced robotics are offsetting higher local labor costs. Finally, customer expectations around sustainability and traceability favor shorter, more transparent supply chains. The bottom line is, while tariffs are a consideration, reshoring decisions are really about strategic flexibility, risk management, and staying competitive over the long term.

Reshore with a Partner You Can Rely On

At PRIDE Industries, our US-based, state-of-the-art facilities minimize your risk of supply chain disruption, optimize manufacturing and fulfillment processing, and provide flexible, on-demand inventory schedules. Partner with us to better manage the unpredictability of tariffs, component availability, and shipping costs—while meeting customer demand for products made in the USA.
Learn More

The first manufacturing robot was installed in a General Motors plant in 1961. Called Unimate, it was able to stack hot die-cast metal pieces accurately, but that was all it could do. Since then, robots have come a long way, taking on jobs previously done by humans: precisely building small electronic components, washing windows on high-rise buildings, or assisting surgeons in the operating room. Purina even fittingly employs a quadruped “dog” robot, dubbed Spot, that can literally climb stairs as it makes routine inspections. Now collaborative robots (cobots), which are designed to work alongside humans, are taking robotics in yet another direction. Cobots in manufacturing are boosting flexibility, productivity, and safety—often at a fraction of the cost of traditional manufacturing robots.

With their flexibility, affordability, and ease of use, cobots can be a powerful manufacturing solution for companies of all sizes.

Because of their ability to work alongside humans and enhance human output, cobots in manufacturing are a fast-growing segment of the robotics industry. Fueled by shortages of qualified workers as well as increasing labor costs, the cobot market is expected to explode from $1.5 billion in 2023 to $23.5 billion by 2033, according to Tech Target. Automation—especially in the industries of healthcare, manufacturing, and logistics—is one of the primary drivers for the growth of these collaborative machines.

When is a Robot a Cobot?

While they are a segment of the robotics industry, cobots are different from traditional industrial robots. Cobots, by definition, are collaborative, intentionally designed to physically interact with humans in a common workspace. While a traditional robot may be designed to replace a human, a cobot is made to augment human capabilities with extra precision, strength, and data capability. Simply put, cobots allow humans to do more.

Cobots have many of the capabilities of traditional robots, with the addition of enhanced safety features that make them suitable for collaborative applications. These features include one or more of the following:

  • Safety Monitored Stop—enables the cobot to halt motion when safety parameters are triggered
  • Hand-Guided Programming—allows an operator to program the cobot by manually guiding it
  • Speed and Separation Monitoring—enables the cobot to adjust its speed based on its proximity to humans
  • Power and Force Limiting—triggers a drop in the cobot’s power or force to prevent harm to humans or objects

5 Advantages of Cobots in Manufacturing

Cobots in manufacturing usually have an arm with joints that allow the arm to bend, rotate, and extend. These cobots are ideal for assembly, machine tending, and product quality inspection and control, and they offer many advantages over traditional robots.

  • Safety: Traditional robots routinely work at high speeds and quickly perform repetitive tasks. Unfortunately, these speeds can pose immense danger to humans, necessitating safety measures like fences to keep humans separate—and safe—in their presence. In contrast, cobots are specifically designed to collaborate with humans and comply with enhanced safety standards. For example, fenceless cobots, also known as speed-and-separation cobots, have laser scanners that create safety zones around their workspaces. These scanners detect when a person is nearby so that the cobot can stop or slow down to avoid an accident. Likewise, speed limits, power limits, and ergonomic designs all contribute to the safety of cobots.
A closeup of a cobot working on a device assembly.
Cobots cost less than traditional robots, with payback periods measured in months not years.
  • Flexibility: Cobots are much more flexible than traditional industrial robots. For example, they can more easily be re-programmed to perform different tasks. Likewise, their smaller size makes them adaptable to multiple workspaces. This flexibility can be especially useful for mid-sized businesses that might not have a level of production that justifies large, dedicated automation systems. For these businesses especially, flexibility helps justify an investment in robotics.
  • User-Friendly: Gone are the days when you needed to be a technical expert to take advantage of digital technology. Today, an iPhone can act as a human-machine interface for your glucose monitor, your washing machine can send you a text for required maintenance—and an average factory worker can reprogram a cobot. To do this, a worker simply guides the cobot through the required paths and positions to complete the new task. The cobot literally learns by doing. Hand-guided programming is one of the breakthroughs that has made cobots practical. And it’s especially useful in situations where a cobot needs to move between stations to accomplish different tasks, as it eliminates the extensive downtime traditionally required for reprogramming.
  • Lightweight and Compact: Cobots are lighter than traditional robots, allowing them to be easily moved and positioned. Likewise, they are more compact, enabling them to fit into tight workspaces and existing workstations. These attributes make it easier for manufacturers to integrate automation into an existing workspace, without the need for major modifications to a facility. 
  • Cost/Return on Investment: Automate.org reports that the positive cash flow from robotic systems can turn a $250,000 investment into approximately $1.5 million of positive cash flow by the seventh or eighth year, primarily through labor savings and productivity gains. Yet, despite the exponential payout from robotics, not all companies desire—or have the means—for the large initial investment required of traditional industrial robots. Cobots, however, cost a fraction of their traditional robotic counterparts, meaning payback periods are measured in months not years. So, while a fully automated smart factory may be the ideal for a large company, cobots are leveling the playing field for medium-sized companies.

Cobots in Manufacturing are Boosting Efficiency

Cobots in manufacturing are bringing increased efficiency to many industries. In the car industry, for example, cobots are the newest automotive technology to be added to the factory floor. Passenger safety is a top priority for car manufacturers, and even a small misalignment on a critical part during assembly can compromise a car’s safety. Cobots, working alongside humans, can add precision and accuracy that are beyond human capabilities.

One example of cobots in action is at BMW Group’s Spartanburg site in Greer, South Carolina. At this manufacturing plant, four cobots equip the insides of the BMW X3 model door with sound and moisture insulation. Previously, workers used a manual roller to adhere the insulation. This highly labor-intensive task is now performed by systems with roller heads on robot arms. The cobots can handle the job with much more precision—better protecting the electronics in the door and the entire vehicle against moisture.

“Robots that assist production workers by assuming labor-intensive tasks will characterize the factory of the future,” explains Harald Krüger, member of the Management Board of BMW AG. “Their benefits are strength and mechanical accuracy—and they perfectly complement humans’ flexibility, intelligence, and sensitivity.”

5 Tips for Integrating Cobots in Manufacturing

Before investing in cobots, it’s important to make a detailed plan for implementation, and to develop well-defined protocols for equipment maintenance. Here are five issues to keep in mind when developing your plan.

  • Set Goals and Key Performance Indicators: Before jumping in with a cobot purchase, you need to define clear goals and key performance indicators. What will success look like? What are you trying to accomplish? In setting your goals, remember to include qualitative as well as quantitative goals. For example, in addition to setting a goal for an increase in units produced, set goals like improved employee safety or increased employee satisfaction.
Hand-guided programming means factory workers need only minimal training to reprogram cobots.
  • Understand the Limitations: According to Ron Potter, Director of Robotics Technology for Factory Automation Systems, Inc., “many people don’t understand that collaborative robots are not a direct replacement for conventional robots.” While cobots have many unique advantages, keep in mind that cobots can’t compete with traditional robotic systems in some areas. For instance, your company needs to set realistic expectations for payload and speed when working with cobots in manufacturing.
  • Choose the Right Cobot: Cobots in manufacturing vary in size, power, price, precision, and functionality. The right cobot for you will likely depend on your budget and the problems you are trying to solve. If the world of automation is new to you, you may want to consult with a robotics specialist or an experienced integrator.

    Keep in mind when choosing a cobot that you aren’t just planning for the present. You need to account for compatibility with future expansions as well as existing systems. Fortunately, the versatility of cobots in digital manufacturing—the integration of digital technologies into the manufacturing process—can make the transition process less painful. Since cobots can easily be reprogrammed, they make it simple to meet changing production needs without significant additional costs or downtime.
  • Involve your current employees: In your automation journey, it’s important to involve your current employees. Your transition will go more smoothly if you emphasize that automation is not about employee replacement. Instead, it’s a way to allow employees to focus on higher value-added activities rather than the manual, repetitive, mundane tasks that can be given to robots. Another way to gain employee buy-in is through employee feedback. For example, most companies will need to analyze current manufacturing processes before choosing a cobot. Therefore, if you are doing a time-and-motion study to identify bottlenecks, don’t forget to solicit employee input. Employees can be one of the best resources for identifying tasks that are repetitive, dangerous, or labor-intensive—and therefore possibly a good fit for a cobot.
  • Develop a Detailed Road Map/Plan: You will need a detailed plan to keep all parties coordinated throughout the implementation process. This plan should include a timeline, a clear definition of roles and responsibilities, and steps to address potential risks. Your plan should also outline the parameters for a simulation test. Fortunately, specialized software is available that will allow you to create realistic simulations of your production process without risking production delays or defective products as you prepare for full cobot integration.

    Your road map should also include instructions for the actual integration, including proper employee training. And your plan shouldn’t end at cobot integration. Be proactive in monitoring and maintaining your new robotics system—establish a schedule for preventive maintenance and address problems promptly.

Because of their ability to leverage the best of humans and robots, cobots are here to stay. Through seamless integration with human workers, cobots are enhancing safety, productivity, and efficiency. With their flexibility, affordability, and ease of use, they are providing powerful solutions for companies of all sizes that are seeking to take advantage of the world of automation. Manufacturers that develop a detailed cobot integration plan—and prepare their human workers in advance—will be poised to take advantage of the cobot evolution that is underway.

A Manufacturing Partner You Can Rely On

PRIDE Industries offers an in-house design team, certified engineers, and a dependable workforce. Learn how you can receive all the benefits of automation and skilled labor—without unnecessary capital outlays.
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The humble cable harness is an unsung hero of electronics products, quietly doing its work to keep wires connected to power sources and linking components to ensure smooth, reliable, continuous operation. Cable harnesses organize and streamline wires within products and are critical to long-term performance. Cable harnesses may seem simple, but as products become more sophisticated and components continue to shrink in size, they are becoming more complex, able to work in challenging environments that require corresponding sophistication in design and assembly.

Benefits of Cable Harnesses

Cable harnesses are common in electronics products because of their many benefits. Well-designed and manufactured harnesses improve product production and performance in the following ways:

Choosing a strong cable harness manufacturer is critical to overall product quality and performance. Here's what to look for.

  • Decrease cost compared to manually installing wires one at a time.
  • Reduce installation time for projects involving extensive networks of wiring or cabling.
  • Improve the organization of cables, making identifying and maintaining connections easier.
  • Protect conductors from the elements outdoors or from chemical and moisture exposure indoors.
  • Reduce strain and stress on connections by supporting the weight of cables.
  • Improve safety by minimizing the risk of shorts or electrical fires.
  • Decrease installation and maintenance time by minimizing the number of connections and organizing components in a logical configuration.

Simple design principles amplify the benefits of wire harnesses. Sheaths protect wires against abrasion or exposure to hazards, minimizing the risk of failure. Connectors, clips, lacing, and other organizational elements reduce the space that wiring needs and ensure that technicians can easily locate components when needed.

Given the important role the cable harness plays in electronics devices, choosing a strong cable harness manufacturer is critical to product quality and performance. Here’s what to look for in a manufacturing partner.

Cable Harness Manufacturing Experience

No surprise here. The best cable harness manufacturers are usually the most experienced. While that may seem obvious, not all experiences are equal. For example, different industries have different safety and compliance requirements. Cable harnesses in the medical device industry must use approved components (wires, cables, interconnects, terminals, etc.) and meet high quality and performance standards. The automotive industry has its own material requirements for harnesses, due to high-temperature engine applications and the presence of corrosive gases and liquids, vibration, and exposure to outdoor elements like rain and snow. So make sure that your cable harness manufacturer has experience and a strong track record in your industry.

An electronics engineer talking with two customers as they stand at a worktable looking at a prototype electronic device
Your cable harness manufacturer should have experience and a strong track record in your industry.

Cable Harness Manufacturing Certifications

Close behind experience comes certifications as an important consideration for selecting a cable harness manufacturer. Manufacturers must comply with the markets’ regulations and demonstrate a track record of creating products that pass industry testing labs. You should expect your manufacturer to have the necessary certifications for producing the type of cable harness you need. These include: 

  • IPC: IPC is a trade association and standards body for electronic equipment and assemblies’ production requirements. IPC/WHMA-A-620 is the international standard for best practices and requirements for manufacturing cable harness.
  • ISO 9001: This is the international standard for a quality management system (QMS) in multiple industries, including cable harness.
  • UL/CUL: Underwriters Laboratories (UL/CUL in Canada) verify that products comply with safety standards for the United States and Canada, respectively. UL/CUL is the largest and oldest independent testing lab in the U.S. and its certifications are recognized by OSHA.
  • ETL: The Electrical Testing Lab (ETL) is another private lab recognized by OSHA that ensures products meet quality, health, environmental, safety, and social accountability standards.
  • ISO 13485: ISO 13485 is the international standard for quality requirements for medical device manufacturing.
  • TL9000-H 6.0/5.0: This is the quality management system for the telecommunications industry.
  • AS9100 REV D: The quality management system for aerospace manufacturing products.
  • ITAR: For aerospace and defense products, the International Traffic in Arms Regulations (ITAR) control the sale, manufacture, and distribution of defense and space-related services and materials on the United States Munitions List (USML).
  • RoHS: The Restriction of Hazardous Substances Directive (RoHS 1) guides the restriction of hazardous substances in electrical and electronic equipment in the European Union.

IPC/WHMA-A-620 is the most widely recognized standard for cable harness manufacturing and the most important certification for a manufacturer. Adhering to this standard ensures product quality, reliability, and consistency. 

Cable Harness Components

While a cable harness may look like little more than a bundle of wires, it is, in fact, an intricate system of components—a subsystem within electronics products. Key components include:

  • Wires: Also called conductors, wires (usually copper) transit electrical signals and power. The choice of wire gauge, insulation material, and strand count can significantly impact the harness’s performance and flexibility.
  • Connectors: Fasteners that simplify the connection between wires and other components, acting like plugs to ensure secure connections.
  • Terminals: Metal components attached to the end of the wires that link to connectors to complete the connection.
  • Sleeving: Coatings protect wires from external elements, abrasions, and other potential damages.
  • Ties and Clamps: Straps that organize and support the wires within the device to reduce strain and facilitate maintenance when needed.
  • Ferrules: Tubes crimped over stranded wires to secure the strands within a screw terminal.

Cable Harness Wire Connections

Cable and harness assembly typically requires connecting different wires to enable electrical current to travel through the connection. The most common methods of connecting wires are soldering and crimping. Both processes help create secure connections for cables, and they produce long-lasting and high-performing cable connections.

Crimping

Crimping is the process of installing connectors on the ends of cables using a crimping tool, and involves stripping, cutting, and crimping terminals on either side of the wires. Whether manual or automated, proper wire crimping requires specialized tools and materials and must follow certain steps. High-quality crimps form gas-tight joints, which result from compressing specially designed splice bands or crimp terminals with cables and wires. Gas-tight connections prevent corrosion from moisture and oxygen.

Terminal crimping reshapes the strands in a wire to form a low-resistance electrical connection. The connections must be strong, with a single joint that has no breaks or segments, and the crimp must meet the height and width specifications established by the terminal manufacturer. It is important to avoid overly tight connections, as this can reduce the cross-section of the wire.

Soldering

Soldering is a traditional wire termination method and can be more cost-effective than crimping. With this method, alloys of tin, silver, or lead are heated and used to create durable joints that connect contacts to wire conductors. Soldering is commonly used in applications that require dependable power and signal connections.

While soldering offers certain benefits such as affordability, some disadvantages of soldering include:

  • Risk of heat-related damage in the connector, contacts, and cables
  • Risk of compromised connections due to vibration and corrosion
  • More time consuming than crimping
Traditional soldering can be more cost-effective than crimping.

Cable Harness Manufacturing Design

Make sure the manufacturer you choose has an experienced engineering and production team capable of producing cable harnesses that meet design specifications and maintain high-quality standards. For example, one of your first decisions is whether to use automated or manual cable harness assembly. You can automate some steps in cable harness manufacturing, but manual production remains common. Automation is used more often when manufacturing at high volumes and using standard connections. However, complicated or non-standard connections can be produced more cost effectively by hand. Knowing your electronics manufacturer has the tools, know-how, and flexibility to design and produce the right cable harnesses for your device is critical to the success of your product.

Cable Harness Materials

The specific material used in a harness largely depends on its surrounding environment. If the wires are in an environment where moisture is present, for example, the harness should be of a material that is water resistant, such as polyethylene. Cables exposed to vibration or movement that might cause abrasion should be enclosed in a harness with a heat-shrink coating to minimize the effects of chafing. Some of the most common cable harness materials include:

  • Polyvinyl Chloride (PVC): PVC is a popular choice for low and medium-voltage wires and is common on indoor telecommunication cables due to its resistance to heat and moisture.
  • Fluorinated Ethylene-Propylene (FEP): FEP is tough and weather resistant, yet flexible. It’s also heat resistant, has dielectric properties, and is chemically inert.
  • Polyethylene: Polyethylene is lightweight, chemically inert, and ideal for high voltages. Polyethylene is available in different densities and has dielectric properties.
  • Nylon: Nylon is a popular choice because it resists weather elements, moisture, abrasion, and chemical reactions.
  • Thermoplastic rubber: A rubber material that stretches easily and returns to its previous state after stretching. It is also usable in high temperatures and resists damage from weather, chemicals, and aging.

There are many more options. Your manufacturer should be knowledgeable about cable harness materials and guide you to the right one for your application. 

Cable Harness Supply Chain

Supply chain concerns impact every aspect of electronics manufacturing, including cable harness manufacturing. Make sure your cable harness manufacturer has access to the parts you need. Verify delivery times and costs. Check to see if they have multiple sources in multiple geographies to hedge against political, social, or climate disruptions. Supply chain management is another area where a design team can add value. Design engineers can propose alternative parts that are more widely available, cost less, or are less at risk of supply chain disruptions.

Cable Harness Testing

Bundling and connecting cables in harnesses creates multiple points of potential failure, making testing and inspecting finished products crucial to ensure consistent, reliable performance. Your cable harness manufacturer should have a robust testing and quality control process in place that includes:

  • Incoming material inspection: Make sure all materials received are in good condition. Defects to look for include:
    • Damaged insulation
    • Incorrect cable sizes
    • Corrosion
    • Moisture
  • Design testing: Ensure that the components in the harness assembly are suitable for the harness design.
  • Label verification: Check that the cables are properly labeled to avoid incorrect connections.
  • Hipot testing: Verify a cable’s ability to withstand high voltages.
  • Voltage Standing Wave Ratio (VSWR) testing: For RF and coaxial assemblies, check that radio frequencies don’t change when passing through the assembly.
  • Continuity testing: Test for circuit opens and shorts to ensure end-to-end signal integrity.
  • Resistance testing: Make sure resistance remains in acceptable ranges.

Critical Role of the Cable Harness

Cable harness assemblies are critical to electronics manufacturing. They are the vital conduits for electrical signal and power transmission and are integral to the functionality of every electronics product, from simple transistor radios to sophisticated spacecraft. The stability and reliability of wire connections keep products operating and safe. In short, electronic products are only as good as the performance of their components and the cables that connect those components. 

Harness Excellence in Electronics Manufacturing

PRIDE Industries has years of experience in electronics manufacturing and cable and harness assembly across multiple industries. We have in-house engineers who can advise when certain crimp terminals would be better done manually due to the intricacy of the terminal or production volume. With a large library of manual and automated tools and customizable facilities, we can offer versatility and cost savings for prototyping and low-volume requirements. And because we set our standards high with IPC inspections and ISO certifications for quality control, you can rely on us to get your product right.
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Automotive Parts Manufacturer Finds Long-Term Manufacturing Partner

InterMotive Vehicle Controls is an automotive parts manufacturer that makes sophisticated vehicle control technology for public safety and transportation vehicles. When the company was looking to outsource production of components of its products, the company struck gold with an inclusive workforce provided by PRIDE Industries.

The Challenge: Consistent, Public Safety-Level Manufacturing

After working for years for Ford Motor Company, Greg Schafer, along with his spouse Linda, launched  InterMotive Vehicle Controls in Auburn, California. As the company grew, they were searching for an automotive parts manufacturer partner to assemble some of the company’s PCBAs and cable assemblies. Finding a company that could provide the quality InterMotive needed for products that must withstand the rigors of public safety and public transportation use, and that could scale with the company’s growth, proved challenging.

The Solution: A Reliable, Skilled Automotive Parts Manufacturer

In 2003 InterMotive discovered PRIDE Industries, a contract electronics manufacturer with a mission to create employment for people with disabilities. “The company’s capabilities blew me away,” Greg Schafer said. “The people, the processes, and the technology are state of the art. But what sets PRIDE Industries apart are the people—I’d never seen a manufacturing floor where employees were so happy to be there.”

The Result: A Long-Term Partnership

Fast forward 20 years, and PRIDE Industries now manufactures 46 parts for InterMotive—24 cable assemblies and 18 mid to high-volume PCBAs. Services provided include functional testing of PCBAs, using custom text fixtures designed and built by PRIDE Industries engineers. Testing time has been reduced from about six minutes to 2.5 minutes, and returned boards have all but disappeared.

“We have directly hired people with disabilities and outsourced to PRIDE Industries for going on two decades now,” Linda Schafer said.

“I have employees with disabilities who started after high school and are now married and buying homes,” Greg Schafer said. “They love their jobs, show up on time every day, and are proud of their work. They really enhance our workforce.”

Vehicles for People with Disabilities

Coincidentally, one of InterMotive’s flagship products is a wheelchair interlock—a mechanism that immobilizes wheelchair-accessible vehicles when the wheelchair ramp deploys. “Some of our employees come to work in vehicles with our products on board,” Linda Schafer said, “products they may have helped build.” InterMotive is the largest manufacturer of wheelchair interlocks in North America. 

Services Provided

  • PCBA and cable assembly
  • Functional testing
  • Custom test fixtures
intermotive automative parts manufacturer logo

Highlights

“The company's capabilities blew me away. The people, the processes, and the technology are state of the art. But what sets the PRIDE Industries apart are the people—I'd never seen a manufacturing floor where employees were so happy to be there.”

— Greg Schafer, Cofounder and President, InterMotive Vehicle Controls
24
cable assemblies
18

PCBAs

Testing time

reduced from 6 minutes to 2.5 minutes

99%

accuracy

Laser Manufacturer Improves PCB Contract Manufacturing Quality, Delivery Times

PRIDE Industries provides PCB contract manufacturing for Vortran Laser Technology, a company building ultra-reliable, high-performance laser solutions for the biomedical, medical, and industrial markets.

The company’s high-precision lasers perform cutting-edge scientific research such as flow cytometry, which analyzes cells by measuring their response to light; and optogenetics, where a laser activates light-sensitive proteins, called opsins, to control the activity of cells in living organisms. 

The precision required to target invisible objects with an accurate beam requires equally precise printed circuit board (PCB) manufacturing. Parts need to be close to perfect.

The Challenge: PCB Contract Manufacturing Quality, Delivery Times

In 2020, Vortran had many issues with its PCB contract manufacturing partner. “Delivery times and quality were slipping, and costs kept increasing,” said Managing Director Chris Kruger. Unpredictable delivery schedules compromised Vortran’s ability to meet deadlines, and since the PCBs control laser performance, substandard quality is unacceptable. 

“Our lasers need to be ultra-stable and reliable for 20 to 30 hours at a time,” Kruger said. “They have to deliver an absolute reference point for researchers.”

The Solution: Customizable Boards Save Time and Money

Kruger and Vortran turned to PRIDE Industries to improve on all fronts.

“We immediately improved delivery times and quality by 50 percent,” Kruger said. “And we were able to cut costs by 10 to 15 percent.”

Kruger worked with the PRIDE Industries electronics manufacturing team to develop a flexible PCB platform that allowed Vortran to use similar boards it could customize for specific products in the assembly process. The solution streamlined purchase orders and enabled higher volume purchases of platform parts to reduce costs and inventory. And reducing the number of boards to order helped mitigate supply chain strains during and after the pandemic.

Results: A Robust Supply Chain

“A significant benefit PRIDE Industries has delivered is having a robust supply chain,” Kruger said. “We have access to the parts we need, and the team is very good about communicating and anticipating any issues that might impact delivery times.”

But the biggest success factor is quality. “Before working with PRIDE Industries, we had to build a 15 percent excess to account for poor yield,” Kruger said. “That’s gone now. The technology—inspection and manufacturing tools—that they use and the quality they deliver are state-of-the-art.”

“We’re a relatively low-volume PCB manufacturer and appreciate that the PRIDE Industries team works with us to manage our runs and inventories so that it works for them as well,” Kruger said. “It’s a real partnership that is hard to find, especially compared to offshore manufacturers.”

Services

  • PCB Contract manufacturing
PCB contract manufacturing: Voltran Laser Technology logo

“We immediately improved delivery times and quality by 50 percent. And we were able to cut costs by 10 to 15 percent.”

— Chris Kruger, Managing Director

Highlights

10-15%

cost savings

50%

improvement in delivery times

50%

better quality