CASE STUDY: MEKOPRINT – ASSEMBLY TABLES FOR CABLE HARNESS PRODUCTION

About the Client

Our client, Mekoprint Cables sp. z o.o., is part of a large international group that manufactures custom electronic, mechanical, and electromechanical solutions for a wide range of industries, including cable harness production.
Mekoprint operates 13 modern production facilities across Europe, including in Poland and Ukraine, with a total floor area exceeding 45,000 m² and more than 750 employees worldwide. The company is a recognized global player in its field, known for its strong values: creativity, innovation, solid foundations, and long‑term partnerships aimed at developing efficient and environmentally responsible solutions.

This philosophy aligns perfectly with Jabama’s own principles, allowing us to quickly find common ground and establish a lasting business relationship built on shared values.

Client Needs and Expectations

The client sought highly customized solutions to improve the efficiency of their cable harness production processes. They clearly outlined what they needed, and we were ready to deliver it.

Key project goals:

1. Develop an ergonomic and adjustable assembly workstation for cable harness manufacturing that:
• Provides flexibility for installing various types of mounting boards.
• Features electric height and tilt adjustment for the work surface.
• Includes customized add‑ons and accessories for tool integration and additional storage space.

Achieving this level of ergonomics and configurability required a workstation with multiple electric adjustment functions and specialized accessories - a challenge only a few companies in Poland can meet.

Beyond cable assembly tables, the client also needed universal workbenches with electric height adjustment and accessories such as tool cabinets, overhead lighting, and cable channels. Some tables were to be customized for installing specific machines used in production, requiring precise cutouts in the worktops. These solutions demanded creative engineering to ensure structural integrity, vibration control, and functional design within electric column systems. 

Challenges

Integrating electric adjustment for height and tilt called for multiple synchronized mechanisms. We based the design on Jabama’s "Spider" assembly table, originally created for electrical and control cabinet assembly. This model offers electric adjustment for both height and frame angle, supported by a steel profile frame with extendable arms that allow easy depth adjustment of the work area.

This adaptable structure proved ideal for the client’s needs. The frame securely holds various mounting panels — in this case, boards for cable harness assembly — using dedicated clamping holders. By expanding or narrowing the frame, operators can easily switch between different board types.

The electric height adjustment allows the workstation to adapt to individual operators, a crucial feature for multi‑shift facilities. It enables comfortable switching between seated and standing positions, supporting worker health and productivity.
Meanwhile, electric tilt control enhances ergonomics even further by improving:

• Operator reach and visibility of installed components.
• The precision of certain assembly tasks thanks to the angled surface.

Lighting posed another challenge. The client required central overhead lighting strong enough to illuminate the work area but not cause glare. They measured the ambient lighting in their plant and provided us with specifications, allowing us to adjust luminance to an optimal, comfortable level.

The upper lighting frame also served as a base for installing an overhead shelf with low aluminum borders (to prevent parts from falling), as well as a cable channel with sockets, surge protection, and quick‑connects. These power outlets are useful for connecting laptops or handheld tools.
Additional storage was provided by side shelves and compartments below the main frame for tool organization. All side and top shelves were extendable, allowing quick access to tools even when a large assembly board is mounted on the table.

At the client’s request, we also produced a dual workstation version — two mirrored tables integrated into one shared frame for cooperative assembly work.

Additional Specialized Workstations

In addition to the cable assembly tables, we designed a custom workstation for a specific production machine. The tabletop was divided into three zones:

• Two side areas with small raised‑edge tops.
• A central zone with a precisely cut opening matching the size and shape of the client’s machine.

This table was fully custom‑built to the machine’s dimensions, demonstrating the benefit of Jabama’s flexible production model — every product can be fully parameterized to match the customer’s equipment.

Because part of the tabletop was replaced by the machine’s footprint, we added movable arm‑mounted shelves to create additional workspace for tools or documentation. These adjustable shelves improve operator comfort and help organize frequently used items.
The workstation was also fitted with a custom cable channel configured with the required number of sockets and quick‑connect options.

Project Results

1. 100% customized assembly stations designed specifically for cable harness production and machine integration.
2. Electric height and tilt adjustment delivering superior ergonomics and increased production efficiency.
3. Adjustable clamping frame allowing quick adaptation to different mounting boards.
4. Extendable shelves improving organization and keeping tools within easy reach.
5. Optimized overhead lighting supporting precision work.
6. Custom cable channels with sockets and quick connectors for smooth equipment integration.

Summary and Reflections

This project was defined by close collaboration and clear communication. The client participated actively in the design process, ensuring every requirement was fully understood and validated. Our engineering and sales teams worked hand in hand with Mekoprint’s representatives, maintaining steady communication that allowed us to incorporate feedback in real time.

Before production began, we provided a comprehensive offer including 3D visualizations and technical drawings. Once approved, we carefully executed the project, inspecting every workstation through rigorous quality control and testing before delivery.

The client tested our solutions in actual production conditions and provided very positive feedback, leading to an ongoing partnership. Since completing this project, we’ve successfully carried out many additional implementations together.

The resulting workstation not only perfectly supports cable harness assembly, but also serves as an optimal solution for control cabinet manufacturers, where Jabama’s “Spider” tables have become a reliable, ergonomic, and versatile choice for complex assembly operations.