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Hayakawa New Premises

Hayakawa, one of the UK’s leading manufacturers of wire harnesses, has doubled the size of its operational facility by moving to larger premises in Wrexham, North East Wales. The relocation will provide much needed space to drive ongoing growth and enable the company to rapidly respond to market demands.

Hayakawa is now taking the opportunity to implement many best practices associated with lean manufacturing. The company’s warehousing facility has more than doubled, which will greatly improve efficiencies for technicians and operators. The manufacturing and warehousing divisions will be located strategically to increase productivity and enhance collaboration throughout the workforce. The facilities for Hayakawa’s administrative division have also significantly increased.

Specialising in the design, manufacture and supply of wire harness and cabling solutions, as well as PCB assembly, Hayakawa plans to create further job opportunities to accommodate the company’s anticipated growth. A number of roles will be created by the end of 2016.

Commenting on this latest investment, managing director Phill Harry, said: “Demand for high quality wire harnesses has been increasing across a number of sectors, including commercial vehicles and UK manufacturing. Moving to larger premises enables us to respond to this demand quickly whilst supporting the needs of our expanding workforce. We are implementing a range of 5S and lean manufacturing techniques during this relocation to ensure we really maximise this opportunity to improve our operational efficiencies and deliver the best possible service to our valued customers.”

Hayakawa recently celebrated its 50th anniversary and this relocation is set to see the company enjoy continued growth and prosperity. The company’s highly experienced engineering team offers unparalleled expertise and is looking forward to working closely with clients at the new manufacturing facility.

As the global economy continues to make its recovery, Hayakawa is working at the forefront of high value engineering to support and strengthen growth in the UK automotive manufacturing industry.

Maintaining a competitive advantage is vital to UK companies operating in fast-paced global markets and high on the agenda is finding new, innovative ways to improve performance, drive manufacturing efficiencies and reduce expenditure. With a commitment to delivering high value engineering that demonstrates tangible and beneficial results, Hayakawa has brought a host of innovations to the UK automotive manufacturing sector that are providing both performance enhancements and cost savings.

Recently, Hayakawa was invited to review the wire harnesses being used by a leading manufacturer of industrial vehicle seats. Having assessed the existing control unit, Hayakawa quickly identified the need to swap certain materials and re-design the circuits. The project involved reducing the quantity of connectors used by changing the circuit and combining connection points; replacing over specified connectors with more common generic alternatives to meet the provided design requirements; improving harness routing to eliminate excess wire usage; and combining separate harnesses into one. Comprehensive diagrams and justifications were provided throughout the project to demonstrate the full breadth of objectives achieved.

Having realised 25% cost savings per annum across eleven items, the client’s purchasing manager said: “We have worked with Hayakawa since 2006 and have always found the company to be proactive and professional in its ability to meet our ongoing cost saving and innovation requirements in a timely and methodical manner. On this specific project, Hayakawa worked closely with my team, the Engineering and Production teams to fully understand the function of our system so they could then develop a cost effective and innovative improvement to the existing arrangement. In doing so, Hayakawa has helped to keep us ahead of its competitors in terms of innovation, technology and comfort in the off highway vehicle seating industry.”

Commenting on Hayakawa’s commitment to high value engineering across a range of sectors, Managing Director Phill Harry said: “Despite the economic downturn, UK manufacturers are functioning with market leading expertise and increasing industrial capability. Only by continually evolving, analysing, assessing and improving will true competitive advantage be achieved. Through value engineering, we are not only supporting the supply chain but introducing best practice manufacturing and installation techniques for processors, developers and manufacturers, which achieve efficiencies and questions what is truly possible.”

Hayakawa designs and manufactures wire harnesses and cables, with a specialism in delivering high value engineering, for automotive, rail, appliance manufacturing and renewable energy sectors. The company also provides a competitive PCB assembly service and the sale of electromechanical components.

Hayakawa, a leading developer of wire harness and cabling solutions, is welcoming 2015 by investing in its people to drive future growth. The company’s UK operation, which was established in 1993 as part of the global Hayakawa group, has worked closely with Skills Growth Wales to create a sustainable organisational structure for the year ahead and beyond.

As part of a Skills Growth Wales programme and with investment from Welsh Government funding, all employees attended comprehensive training to help their personal and professional development. A strategic business model has been developed and implemented, which was supported by training modules that focused on organisational effectiveness.

The foundations for growth were implemented throughout 2014 and at the end of November 2014, the company’s investment in people saw an organic growth of 54%. This growing workforce will be supported by the restructuring of the organisation and the appointment of a Quality Engineer and a Business Operations Manager. These leaders both have extensive engineering capabilities and a strong vision to safeguard the company’s position as a leading force in wire and cable manufacturing across a number of sectors, including automotive and rail.

As well as senior roles, Hayakawa actively promotes career growth amongst graduates and new starters. The company is currently sponsoring a graduate employee’s MBA at Glyndwr University.

Early in the New Year, Hayakawa is set to install 3D CAD to further expand its service capabilities. The company is also investigating the potential of developing its warehouse facility, which could see its complete reconfiguration and the possibility of further employment opportunities in 2015.

Wrexham-based Hayakawa UK has manufactured and supplied wire harnesses for use in a revolutionary refrigeration system that ensures the safe storage of vaccines throughout the world.

Sure Chill, Ian Tansley, Peter SaundersHayakawa has supplied a redesigned wire harness solution for a unique cooling system developed by Snowdonia-based The Sure Chill Company. The highly advanced technology is set to transform the refrigeration, food and beverage, and healthcare industries by bringing reliable cooling to countries without adequate power. The new refrigerators are currently being used to store vaccines in developing nations to help combat life-threatening illnesses such as polio, as well as maintaining the freshness and preventing the damage of food.

Inventor Ian Tansley of Sure Chill, with investment from UK Business Angel Of The Year 2012 Peter Saunders OBE, has worked tirelessly to identify a robust, reliable and cost-effective way to store vaccines, foods and drinks in optimum condition. He has developed an entirely new solution and, unlike traditional fridges that require a continual power source, Sure Chill’s technology needs very little power. It can actively cool without power for over 12 days in an ambient temperature of 32°C. The technology also achieves an even temperature throughout the fridge compartment with no stratification.

During the development of this radically new technology, Sure Chill manufactured wire harnesses in-house on an ad hoc basis, which result in inconsistencies in production. Hayakawa was approached to redesign the wire harness and create a better solution for the company’s mains powered refrigerator. Technicians at Hayakawa reverse engineered the original sample and implemented a number of value engineered concepts to improve the overall performance whilst achieving a cost effective solution. The project delivered a number of significant improvements in assembly for The Sure Chill Company.

Commenting on the successful collaboration, Hayakawa’s Managing Director Phill Harry said, “We are proud to be associated with such revolutionary technology produced by a very forward-thinking and dynamic company. It has been great to work with such a successful and driven Welsh organisation that is helping to save both lives and the planet.”


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*Please note we are not an automotive spares provider for individual harnesses.


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