Evolving Manufacturing That Paves the Way to the Ideal Future
Automation and Local Production Strategy Demonstrated in e-STEALTH W/H™ Manufacturing
From Labor-Intensive Approaches to a Strategy of Optimal Talent Allocation
Wire harnesses are core products of the Sumitomo Electric Group’s automotive business. Sumitomo Wiring Systems is solely responsible for their manufacturing and operates a global supply chain network. Sumitomo Wiring Systems boasts a leading global market share in wire harness manufacturing, often called the nervous system of automobiles. It has 105 locations in 32 countries and regions worldwide and employs approximately 250,000 people. Historically, wire harness manufacturing was a labor-intensive industry requiring a vast amount of manual work, which led to the practice of relocating production to optimize cost. However, pandemic-induced lockdowns and soaring logistics costs exposed vulnerabilities in remote supply models. Kenichi Urushibata, President of Sumitomo Wiring Systems, says it is time to fundamentally rethink the role and location of manufacturing bases to fulfill supply responsibilities.
“Our mission is to continue providing high-quality products at competitive prices, but the business environment has changed dramatically in the last five years. The era of relocating production sites around the world to reduce cost is over. Producing and delivering right next to the market, shifting towards local production for local consumption, is the way to simultaneously strengthen business continuity planning and reduce environmental impact.” (Urushibata)
New Product e-STEALTH W/H™: Revolutionizing Vehicle Structure
For production in advanced economies, automation that addresses higher labor cost is an absolute necessity. However, the conventional structure of wire bundles was extremely difficult to automate. This led to the development of a next generation wire harness with a flat structure, e-STEALTH W/HTM (e-Stealth Wire Harness). The e-STEALTH W/HTM is applied to the main harness of the area harness structure, in which the complex wiring running throughout the entire vehicle is modularized into main and branch harness units. By adopting aluminum conductors, the harness was made lighter; by using fusion technology to arrange the wires flat, space was saved; and the manufacturing process was automated. In practical applications, the flat design, with integration with surrounding in-vehicle components, enabled reducing the height of the instrument panel by approximately 40 mm.
Furthermore, e-STEALTH W/HTM provides a groundbreaking solution to electromagnetic noise, a serious challenge as CASE technologies continue to advance.
“The development of e-STEALTH W/ HTM, conducted in collaboration with ANTech, features an innovative design that arranges wires in a flat, parallel structure. This design reduces electromagnetic noise interference and ensures stable communication quality. In connected vehicles and electric vehicles (EV), this infrastructure technology, which enables stable current flow, represents a key strength for us.” (Urushibata)
Reshoring to Japan and Reclaiming the Role as the World’s Main Mass Production Factory
The e-STEALTH W/HTM has also achieved significant results from a business perspective.
“Instead of transporting bulky finished products, we transport main wiring harnesses in a flat-packed form and assemble them near the point of consumption. This significantly reduces transportation costs and inventory space, improving profitability. This means that Sumitomo Wiring Systems is redesigning itself from simply supplying parts to becoming a system supplier with integrated logistics capabilities.” (Urushibata)
Then, what is Sumitomo Wiring Systems’ future vision centered on e-STEALTH W/HTM?
“The challenge is cost. We must avoid focusing solely on price comparisons of individual parts and instead work closely with our customers from the vehicle’s structural design stage, with e-STEALTH W/HTM adoption assumed from the outset. Moving forward, we will not only expand the scope of application to areas such as underfloor, ceilings, and battery surrounds but also establish a system that can flexibly respond to fluctuations in market demand, including applications in the flying car and robotics sectors. This will impress our customers and put their minds at ease.” (Urushibata)
Furthermore, Urushibata’s vision for the future is the reshoring of production to Japan. By maximizing automation, manufacturing costs can be leveled out, enabling mass production even in Japan where labor costs are high, without relying on overseas production. If Japan can achieve cost competitiveness, it will not only strengthen its supply chain but also reactivate the country as the world’s primary mass-production hub, contributing to the recovery of its economic strength.
“Ideally, a smart factory would assemble the optimal modules by robots immediately upon receiving an order, embodying the ultimate form of local production and consumption. This also represents a challenge to reclaim the pride of Japanese manufacturing.” (Urushibata)
The Sumitomo Electric Group’s proud on-site strengths are now evolving into an unprecedentedly robust infrastructure, powered by digital technology.
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