Highly automated cable assembly, CNC machining and special-purpose machine building from the Erzgebirge.
UNGER Kabel-Konfektionstechnik GmbH
Sehmatal-Sehma (Headquarters, Plant 201) · Sehmatal-Cranzahl (Plant 202/204) · Chemnitz (Plant 206)New on Amplifa
About UNGER Kabel-Konfektionstechnik
UNGER Kabel-Konfektionstechnik GmbH is a medium-sized family company based in Sehmatal (Erzgebirge) specializing in highly automated cable assembly. The manufacturing portfolio comprises core wires, mains cables and appliance connection systems, ABS sensor cables, sensor technology and lambda probes, as well as complete cable sets and cable production by the meter including in-house PVC cable extrusion. In addition, the company produces CNC-machined parts at its Cranzahl plant and is set up for production from prototypes and one-offs through to series of over 100,000 pieces/year; materials include brass, copper, steel and special alloys. The in-house special-purpose machine building division develops and builds fully linked, highly automated production lines for its own production as well as for customers. An in-house research and development department has been supporting prototyping, testing and process development since 2011. The products go to the automotive industry (original equipment, including lambda probes and ABS systems) as well as to industrial applications such as handling systems, special fixtures and special-purpose machines.
- Site
- Sehmatal-Sehma
- Processes
- Cable assembly (core wires, appliance connection systems, cable sets, mains cables), Cable extrusion (in-house PVC meter goods), CNC milling, CNC turning, Bandsaw cutting (external as supplementary in-house service), Vibratory finishing, Washing (tub washing machine), Surface grinding
- Materials
- PVC (Meter Goods, Granulate), Rubber, TPE, PUR, Brass, Copper, Steel, Special Alloys
- Certificates
- IATF 16949:2016 (Cable Assembly, TÜV NORD), DIN EN ISO 9001:2015 (Special Plant Engineering, Cable Assembly, CNC, DIN EN ISO 14001:2015 (Manufacturing/Development of Cables and Mains, DIN EN ISO 50001:2018 (Energy Management, ICG)
- Industries
- Automotive, Electrical Industry/Household Appliances, Industrial Automation (Handling Systems, Packaging Technology, Assembly, Special-Purpose Machine Building
- 01
Research & Development / Prototyping
- 02
Design (Special-Purpose Machine Building)
- 03
PVC Cable Extrusion (Meter Goods)
- 04
CNC Machining (Milling, Turning, Grinding, EDM)
- 05
Highly Automated Cable Assembly in Full Linking
- 06
Assembly / Overmolding of Connector Plugs
- 07
In-Process Testing and End-of-Line Inspection
- 08
Delivery
Materials and Processes
PVC (Meter Goods, Granulate)
In-house cable extrusion of harmonized PVC meter goods for cable assembly.
Rubber
Cable material for single-core and multicore meter goods in various grades.
TPE
Thermoplastic elastomer as cable material in cable assembly.
PUR
Polyurethane as cable material for demanding applications.
Copper
Material for stamped and turned parts as well as machined materials for contact components.
Brass
Material for stamped strips, stamped and turned parts in the contact components industry.
Steel
Material for machinable components including coated and uncoated versions.
Special Alloys
Machining of special alloys for specific customer applications.
Sites
Plant 201 Sehma (Headquarters)
DECable assembly: mains cables and appliance connection systems; ABS sensor cables, sensor technology, lambda probes
- Lot size
- Fully automatic (series), highly automated linked (medium
- Materials
- PVC, Rubber, TPE, PUR, Copper
- Fully linked, highly automated cable assembly production lines
- Handling robots
- Fully automated high-bay warehouse (2018)
- In-house PVC cable extrusion
Plant 202/204 Cranzahl
DESpecial-purpose machine building and CNC machining
- Lot size
- One-off production to series of over 100,000 pcs/a
- Materials
- Brass, Copper, Steel, Special Alloys
- DMG MORI DMC 125U duoBLOCK (5-axis)
- DMG MORI DMC 80U duoBLOCK (5-axis)
- DMG MORI DMF 360 (4-axis)
- DMC 63 vertical machining centers
- Hüller Hille nbh 6 horizontal machining center
- Scherer VDZ 220 XL DS / TWIN 65 twin-spindle turning center
- TSUGAMI BO266-II Swiss-type lathe (bar feeder 3,000 mm)
- Citizen CINCOM L32-1M8 Swiss-type lathe
- ROMI E280 chucking lathe
- HWACHEON VT and ECO 5V R vertical lathes
- Mitsubishi FA20S ADV wire EDM system
- Deckel DE10 die-sinking EDM machine
- SIU5R chucking part grinding machine
- Surface grinding machines Micromat SFW 200×600 and FS 40 AC-SE
- Rösler vibratory finishing system
- Metrology lab: ZEISS MC850 and Wenzel LH1210 coordinate measuring machines, Mitutoyo Contracer CV-2100 M4, Mitutoyo FORMTRACER Avant S-3000, Keyence IM-7020
Plant 206 Chemnitz
DEMains cables, appliance connection systems, cable production as meter goods
- Lot size
- High volumes, fully automatic cable assembly in full linking
- Materials
- PVC, Rubber, TPE, PUR, Copper
- Fully linked, highly automated cable assembly production lines
Components and Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Cable assembly (core wires, appliance connection systems, cable sets, mains cables)Assembly | – | – | – | – | PVC, Rubber, TPE, PUR, Copper |
| Cable extrusion (in-house PVC meter goods)Plastics | – | – | – | – | PVC granulate |
| CNC millingMachining | – | – | – | One-off production – over 100,000 pcs/a | Brass, Copper, Steel, Special Alloys, all machinable materials |
| CNC turningMachining | – | – | – | One-off production – over 100,000 pcs/a | Brass, Copper, Steel, Special Alloys, all machinable materials |
| Bandsaw cutting (external as supplementary in-house service)Machining | – | – | – | – | – |
| Vibratory finishingSurface | – | – | – | – | – |
| Washing (tub washing machine)Surface | – | – | – | – | – |
| Surface grindingMachining | – | – | – | – | – |
| Wire EDMMachining | – | 1,050 mm × 800 mm × 295 mm | – | – | – |
| Die-sinking EDMMachining | – | 810 mm × 510 mm × 240 mm | – | – | – |
| Special-Purpose Machine Building / Special Plant EngineeringEngineering | – | – | – | – | – |
| Internal and external cylindrical grinding (chucking part grinding)Machining | – | – | – | – | – |
| 3D coordinate measurement / Inspection process with measuring and testing equipmentInspection | – | – | – | – | – |
| Research and Development / Prototyping & TestingEngineering | – | – | – | – | – |
| Overmolding of connector plugs / Assembly of sleeves (sensor cables)Assembly | – | – | – | – | Plastic (molding compound) |
| Partner services (in the vicinity, not in-house): flame, laser and waterjet cutting, casting,Surface | – | – | – | – | – |
30 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis machining center | DMG MORI DMC 125U duoBLOCK | 1 | – | – | Plant 204 Cranzahl |
| 5-axis machining center | DMG MORI DMC 80U duoBLOCK | 1 | – | – | Plant 204 Cranzahl |
| 4-axis machining center (swiveling milling head ±90°) | DMG MORI DMF 360 | 1 | – | – | Plant 204 Cranzahl |
| 3-axis vertical machining center | DMG MORI DMC 63 | 2 | – | – | Plant 204 Cranzahl |
| 3-axis vertical machining center | DECKEL DMU 50 T (manually rotatable and swivelable table) | 1 | – | – | Plant 204 Cranzahl |
| 3-axis vertical machining center | Sigma Mission | 2 | – | – | Plant 204 Cranzahl |
| 4-axis horizontal machining center (with U axis) | Hüller Hille nbh 6 | 1 | – | – | Plant 204 Cranzahl |
| 4-axis vertical machining center (CNC rotary table Nikken) | Sigma Ekkon Leader | 1 | – | – | Plant 204 Cranzahl |
| Double machining center / twin-spindle turning center | Scherer VDZ 220 XL DS / TWIN 65 | 1 | Machining length 250 mm | – | Plant 204 Cranzahl |
| CNC Swiss-type lathe with 3,000 mm bar feeder and sub-spindle | TSUGAMI BO266-II | 1 | Bar feeder 3,000 mm | – | Plant 204 Cranzahl |
| CNC Swiss-type lathe with 3,000 mm bar feeder and sub-spindle | Citizen CINCOM L32-1M8 | 1 | Bar feeder 3,000 mm | – | Plant 204 Cranzahl |
| CNC chucking lathe | ROMI E280 | 1 | – | – | Plant 204 Cranzahl |
| CNC chucking lathe (semi-automatic loading/unloading) | CTV 250 | 1 | – | – | Plant 204 Cranzahl |
| CNC vertical lathe | HWACHEON VT | 1 | Max. turning length 525 mm | – | Plant 204 Cranzahl |
| CNC vertical lathe | HWACHEON ECO 5V R | 1 | Max. turning length 525 mm | – | Plant 204 Cranzahl |
| CNC wire EDM system | Mitsubishi FA20S ADV | 1 | max. workpiece size 1,050×800×295 mm | – | Plant 204 Cranzahl (EDM machine fleet) |
| CNC die-sinking EDM machine | Deckel DE10 | 1 | max. workpiece size 810×510×240 mm | – | Plant 204 Cranzahl |
| Chucking part grinding machine internal/external machining (max. 4 CNC-controlled swivel-in tools) | SIU5R SIU5R | 1 | – | – | Plant 204 Cranzahl |
| Surface grinding machine | Micromat SFW 200*600 | 2 | 200×600 mm | – | Plant 204 Cranzahl |
| Surface grinding machine | SE FS 40 AC-SE (200×400) | 2 | 200×400 mm | – | Plant 204 Cranzahl |
| Automatic metal bandsaw | – | 1 | max. bar length 6 m, max. sawing Ø 305 mm, max. cross-section 305×360 mm | – | Plant 204 Cranzahl |
| Vibratory finishing system | Rösler | 1 | – | – | Plant 204 Cranzahl |
| Tub washing machine | – | 1 | – | – | Plant 204 Cranzahl |
| 3D coordinate measuring machine | ZEISS MC850 (modernized by MITO) | 1 | – | – | Plant 204 Cranzahl (Metrology Lab) |
| 3D coordinate measuring machine | Wenzel LH1210 | 1 | – | – | Plant 204 Cranzahl (Metrology Lab) |
| Contour measuring machine | Mitutoyo Contracer CV-2100 M4 | 1 | – | – | Plant 204 Cranzahl (Metrology Lab) |
| Surface measuring machine | Mitutoyo FORMTRACER Avant S-3000 | 1 | – | – | Plant 204 Cranzahl (Metrology Lab) |
| Measuring projector | Keyence IM-7020 | 1 | – | – | Plant 204 Cranzahl (Metrology Lab) |
| Fully automated high-bay warehouse | – | 1 | – | 2018 | Sehma |
| Fully linked, highly automated cable assembly production lines / Handling robots | – | – | – | – | Sehma, Cranzahl, Chemnitz |
Quality and Certification
Quality is ensured through in-process testing during production, systematic end-of-line inspection and zero-defect management. The metrology lab is equipped with 3D coordinate measuring machines from ZEISS and Wenzel as well as measuring and testing equipment from Mitutoyo and Keyence; first article inspection reports and measurement protocols are supplied on request.
| Evidence | Sehma | Cranzahl | Chemnitz |
|---|---|---|---|
| IATF 16949:2016 (Cable Assembly, TÜV NORD) | |||
| DIN EN ISO 9001:2015 (Special Plant Engineering, Cable Assembly, CNC | |||
| DIN EN ISO 14001:2015 (Manufacturing/Development of Cables and Mains | |||
| DIN EN ISO 50001:2018 (Energy Management, ICG) |
Company History
- 1945
Herbert Unger registers an electrical trades business with the city of Annaberg-Buchholz on 14.09.1945.
- 1948
Re-declaration as "Sühnel und Unger" – Richard Sühnel joins as a partner.
- 1961
Richard Sühnel dies; Werner Unger takes over the commercial business.
- 1972
Nationalization: the mechanical engineering division is transferred to SDAG Wismut.
- 1974
Horst Unger continues the company as UNGER Elektroanlagenbau with 12 employees.
- 1991
Founding of UNGER Elektro-Anlagenbau GmbH.
- 1992
Ursula Unger and her sons Heiko and Ronny take over the management (15 employees).
- 1998
Founding of the industrial manufacturing company UNGER Kabel-Konfektionstechnik GmbH.
- 1999
Start of production in the new building.
- 2001
Purchase of a vacant industrial property in Sehma.
- 2006
Completion of the comprehensive refurbishment as Plant 2 in Sehma.
- 2008
New extension building in Cranzahl as Plant 3 for special-purpose machine building and machining.
- 2011
Establishment of an in-house research and development department.
- 2016
Commissioning of the fully linked production of mains connection cables for electric toothbrushes.
- 2017
Start of production at the Chemnitz manufacturing site.
- 2018
Commissioning of a fully automated high-bay warehouse.
- 2019
Expansion with in-house PVC cable extrusion; research into fully automated cable harness routing using handling robots.
- 2020
Capacity expansion in Chemnitz with a focus on fully automatic cable assembly in full linking.
- 2023
Further capacity in Sehma with a focus on fully automatic cable assembly in full linking.