Selecting the Best Termination Tool for Your Needs

Selecting the best termination tool for your needs

April 15, 2025
By Panduit, for the Blue Print

In any manufacturing or assembly process, efficiency and precision are key. Choosing the right termination tool can mean the difference between a seamless workflow and costly errors. But how do you determine which tool is best suited for your needs?

While one manufacturer might use a high volume of terminals, that doesn’t automatically mean a benchtop or fully automated tool is the best option. The decision depends on nuances within the application, such as the workflow at each station, precision requirements, and flexibility needs. In this blog we will discuss the pros and cons of handheld tools, benchtop crimpers, and full automation, and how to determine the best fit for different environments.

Handheld tools: flexibility & mobility

Handheld tools are often viewed as the “entry-level” option, but they offer significant advantages, even in high-volume operations. Their primary strengths lie in flexibility, mobility, and ease of use.

Use Case: Consider an assembly line with multiple workstations producing custom wire harnesses. Although the manufacturer processes tens of thousands of terminals, not every workstation needs a fixed crimping machine. Workers might move between different areas or shift between tasks that require varying levels of precision and tool interchangeability. Handheld tools can be easily carried and adapted to different types of terminals or ferrules on the fly, making them indispensable for low-volume, high-mix production environments.

Key Benefits:

Mobility: Portable for on-the-go crimping across different workstations.
Cost-Effective: Lower initial investment compared to automated or benchtop options.
Flexibility: Ideal for short runs or workstations that require frequent changes in the tooling.

Benchtop crimpers: speed & consistency

Benchtop crimping systems are either designed for loose piece or reel-fed terminations. These systems are best for production areas where products are brought to the tool.

Loose piece bench mount systems offer improved ergonomics by providing hands-free applications where a foot pedal is used to activate the tool. However, these systems require loading each terminal individually into the tooling. Loose piece terminal systems have the largest range of terminal gauge sizes that can be terminated and are ideal for high-mix, low-volume applications.

Reel-fed termination systems offer the highest efficiency of the two benchtop systems by reducing the time to load terminals. This is due to the terminals being fed into the equipment through a carrier strip that acts as a magazine, loading bulk amounts of terminals. Like loose piece systems, reel-fed equipment is hands-free and automatically feeds once the system is activated with a foot pedal. Reel-fed systems are best for low-mix, high-volume applications.

Both loose piece and reel-fed benchtop systems require a secondary wire stripping application before crimping the terminal.

Benchtop tools bridge the gap between handheld tools and full automation. They provide more speed and consistency than handhelds, without the high cost of fully automated systems.

Use Case: Imagine a manufacturer that produces a steady volume of similar wire assemblies at one or more dedicated stations. The operator might stay at a single workstation but requires faster throughput than a handheld tool can offer. A benchtop crimper allows for higher production speeds while still offering manual oversight for precision and quality control. It’s perfect for mid-level production environments where consistency and repeatability are crucial, but the volume doesn't yet justify the expense of a fully automated system.

Key Benefits:

Higher Speed: Faster than handheld tools, with more consistent crimps.
Precision: Suitable for operations requiring exacting standards and reliability.
Compact: Takes up less space than full automation systems while offering faster cycle times.

Fully automated systems: efficiency at scale

Fully automated crimping machines are the go-to choice for high-volume, repeatable applications where speed and minimal manual labor are critical.

Use Case: A major manufacturer producing thousands of identical wire assemblies daily can justify the investment in full automation. In these cases, an automated system can drastically increase throughput while reducing labor costs. However, it’s important to note that full automation isn’t always the right fit, even for large-scale operations. For manufacturers producing different wire configurations or needing flexible production lines, the rigidity of automation can be a drawback.

Key Benefits:

Maximum Efficiency: Ideal for high-volume, repetitive applications.
Labor Savings: Reduces the need for human intervention, driving down labor costs.
Consistency: Guarantees high precision and uniformity across large production runs.

Selecting the right tool for the job

The assumption that a high-volume manufacturer should always use automated tools is a common misconception. The right tool depends on the specific requirements of each workstation and the overall production process.

For Example:

A single factory might use handheld tools in custom assembly stations, benchtop crimpers for mid-level production lines, and fully automated systems for high-volume, low-mix operations.
Flexibility is key in applications where product designs change frequently, or workstations need to accommodate varying tasks.
Distributors play a crucial role in guiding manufacturers to the right tooling solutions by understanding the nuances of their production processes—not just their total terminal volume.

Conclusion

Choosing the right termination tool isn't just about volume—it’s about optimizing your workflow for efficiency, flexibility, and quality. Whether you're working in a high-mix, custom assembly environment or a high-volume production line, selecting the right tool can make all the difference in performance and cost savings.

By evaluating your specific needs—mobility, precision, speed, or automation—you can ensure that your operations run smoothly and efficiently.

Content originally from Panduit. Reused here with permission.