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Data Center Success Story

Scaling High-Mix Wire Harness Production for AI-Driven Data Center Cooling

Background

Rising Demand for Custom Cooling Harnesses

A global data center cooling OEM specializing in liquid cooling and thermal management systems experienced a surge in demand driven by AI workloads. Within a three-month period, MRG received 3-5x higher wire harness orders to support liquid-cooled rack systems.

The increase exposed a production constraint:
manual strip and crimp processes could not support the required volumes, putting throughput and lead times at risk.

The customer needed a fast, scalable way to increase capacity without compromising quality.

Our Approach

Automating the Strip and Crimp Bottleneck

MRG focused on removing the primary production constraints while preserving quality and delivery speed:

  • Identified manual strip/crimp operations as the primary bottleneck limiting throughput and consistency
  • Transitioned to automated strip and crimp processing to increase speed and capacity
  • Partnered with equipment suppliers to deploy automation quickly and reliably
  • Integrated in-line quality monitoring to reduce variation and scrap

Breakthrough Impact

Higher Throughput, Lower Risk, Shorter Lead Times

The automated process delivered immediate and measurable performance gains:

  • 10-15x Faster

    10-15x faster processing with
    automation compared to
    hand strip/crimp

  • Enhanced Reliability

    Driving enhanced reliability and
    quality through consistent,
    uniform crimps

  • Shorter Leads

    Shorter lead times for large, high-mix
    harness builds in liquid-cooled rack
    applications

  • Improved Ergonomics

    Improved ergonomics, eliminating the
    primary source of repetitive stress from
    manual crimping

  • Faster Cycles

    Faster cycle times driven by
    reduced handling and fewer
    manual transfers

Why MRG Won

Rapid Execution Through Engineering & Manufacturing

MRG delivered a scalable solution aligned to the customer’s accelerated growth:

  • Fast, cross-functional execution to remove production bottlenecks quickly

  • Rapid automation deployment to meet a 3-5x demand increase

  • Strong equipment sourcing capability to scale throughput reliably

  • Scalable, customer-focused approach balancing speed, quality, and growth

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