4Wire EAS

Control of complex assembly processes.

The production areas after the cutting area are moving more and more into focus. The manufacturers of cable harnesses need more efficiency, improved quality assurance and more transparency in these areas.

4Wire EAS (Extended Assembly System) delivers all of this. With EAS, complex products, right up to complete cable sets and the associated production plans, can be described. EAS controls production and documents all work steps. Processing standards ensure that uniform procedures and parameters are used. Quality and test plans ensure a high-quality standard.

When 4Wire EAS is used together with 4Wire CAO, the two systems together enable complete documentation of production and comprehensive traceability. 4Wire EAS is extremely flexible and able to control the most varied of production processes such as crimping, twisting, welding or injection molding.

4Wire EAS uses the most modern technologies. Through the consistent use of APIs, 4Wire EAS is very easy to integrate into existing system environments. The user interface is HTML-based, which means that the customer can use simple and inexpensive end devices. The system can be operated both “on premise” and in the cloud.


More information

What does “EAS” mean?

“EAS” stands for “Extended Assembly System”. With EAS it is possible to control and document complex manufacturing and assembly processes. We used the term “extended” to show that the system today is not a replacement for our CAO system, but an extension.

What is the difference between EAS and CAO?

CAO was developed to control the production in the “cutting area”. The articles that are manufactured there are relatively simple in structure. Usually it is a single cable or twisted cable with corresponding crimps at the ends. The work plans are usually one-step.

Much more complex items can be described in EAS, such as assemblies or the complete wire harness. Work plans for the production of these articles can contain any number of work steps and BOM elements.

With EAS, the production steps in areas P2 and P3 can therefore be controlled and documented much better and more precisely.

Which production processes does EAS support?

EAS is designed to be very flexible and generic. The user can define each process himself. EAS can not only support the classic processes such as crimping, twisting and welding, but also any other processes such as injection molding. For each process, the user can define process parameters that are used during execution (process parameters, processing standards).

What machine interfaces are there in EAS?

The first interfaces are already available. This includes interfaces to the leading crimping machines, twisters and welding machines. Further interfaces are constantly being developed. Because even complex items can be described comprehensively, we are now also able, for example, to describe a welding work plan in every detail and transfer it to the machine.

What about machines that don't have a common interface?

Such machines are often found in areas P2 and P3. For any devices that do not offer a dedicated interface, EAS will provide an API for the most common use cases that can be used to give feedback to the MES. These endpoints could be easily used by a generic interface gateway.

EAS also has an interface to the Crimpforce monitors from OES. If these are installed in a machine, we can use them to implement a connection.


How does EAS support quality assurance?

EAS comprehensively supports quality assurance. Processing standards and processing instructions ensure that every process uses the correct parameters. EAS automatically selects the correct parameters depending on given rules.

The user can flexibly define quality assurance measures such as measurements. The system then ensures the correct workflow.

What does EAS offer in the area of "traceability"

Traceability was a very important topic for us. With EAS you can document the entire manufacturing process. Full traceability is possible. We differentiate between “vertical traceability”, ie the information “what components does something consist of” and “horizontal traceability”, ie the information “how was something produced”. EAS masters both. If EAS is used together with CAO, you get traceability from the raw material to the finished wire harness.

Can I also control final assembly with EAS?

EAS will be able to control a series final assembly (built to stock) and also a KSK final assembly (built to order)  in the next year 2022.

Can I integrate EAS into our system environment ?

EAS is an application based entirely on REST APIs. This means that EAS can be easily integrated into existing system environments. Extensive documentation ensures that the customer can do this himself.

What equipment do I need in production to use EAS?

The user interface of EAS runs in a browser. This has the great advantage that you do not need a PC, but can use any device on which a browser is running.

This is a major advantage in terms of cost.

What does EAS cost?

The costs essentially depend on how many workplaces are to be controlled.

We are offering a subscription model for the first time. The customer pays a monthly rent. There are no additional costs.

Customers who already use CAO receive a significant discount.


Thanks to improved order planning, 4Wire EAS results in increased efficiency in the assembly areas.


Process standards and quality control measures ensure high-quality production.


4Wire EAS documents the production process and ensures transparency.


4Wire EAS and 4Wire CAO allow for complete traceability.