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ERKO and OMRON Advance Cable Harness Production with Flexible Automation

Case Study

2/17/2026

Industry

Digital

Application

Assembly

Robot Solution

i4L SCARA Robot

A tailored solution for automated terminal handling, fast changeovers, and consistent quality

ERKO, a manufacturer of cable accessories and electrical connection solutions, set out to automate a demanding part of cable harness production: the handling, sorting, and processing of small terminals across multiple variants. The challenge was not simply throughput. Different terminal types, frequent product changes, and the need for reliable placement created a process that required more flexibility than conventional feeding and handling systems could offer. ERKO needed a solution that could combine precision, repeatability, and adaptability in one compact production cell.

To meet these requirements, ERKO collaborated with OMRON to develop an integrated system centered around the i4L SCARA robot, the FH vision system, and a tailored feeder concept for loose metal components. The solution enables terminals to be identified, presented, and picked in the correct orientation before moving into downstream processing steps. The robot’s speed and repeatability make it well suited to high-cycle handling tasks, while the vision system supports accurate picking and consistent positioning. Together with the feeder setup, the system creates a flexible cable harness automation solution that reduces manual intervention and supports fast product changeovers.

Usability on the shop floor was also a key part of the project. The machine cell includes an OMRON HMI that allows operators to manage recipes and settings in a structured way, helping the system remain practical in day-to-day production. By combining the i4L SCARA Robot, machine vision, and intelligent feeding in one coordinated process, ERKO and OMRON created a production solution that improves consistency while remaining responsive to changing manufacturing requirements.

Watch the ERKO solution in action:

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“The heart of this machine is not only the production line itself, but the entire concept of intelligent, adaptive automation – where universality and full automation go hand in hand.” — Marcin Pawlak, New Product Development Manager ERKO

Results at a glance:

High productivity – up to 200 pieces per hour
Fast changeovers across different terminal variants
Consistent quality with vision-guided robotics
Reduced manual handling in terminal sorting and presentation
Structured operator control through OMRON HMI

Automation tailored to cable harness production

ERKO’s collaboration with OMRON shows how a focused automation concept can solve a very specific manufacturing challenge: handling small, variable components without sacrificing speed or flexibility. By combining robotics, vision, and intelligent feeding in one system, the project delivers a practical model for more reliable and adaptable cable harness production.

For manufacturers looking to automate terminal handling, wire processing, or similar high-variation tasks, this project illustrates what a well-matched automation solution can achieve. Our team is ready to help identify the right approach for your production environment.