Data Cable, a wire harness producer based in Orangeville, Ontario, has a long-standing history in the industry, with origins dating back to the early 1980s. Founded by a husband-and-wife team, the company remained under private ownership for decades before being acquired by a private equity firm in 2021. With nearly 45 years of experience, Data Cable has evolved from serving a small customer base to becoming a supplier for hundreds of clients annually across multiple industries.
The company specializes in wire and cable harness assemblies, box builds and electro-mechanical devices supporting a diverse set of industries including defense, satellite communications, medical equipment, agriculture, mining, oil and gas, and drone manufacturing. As (CEO) Chelliah Purushothaman put it, “We build for any product that needs wires, and frankly, I don’t see any product that doesn’t. Even a wireless product still has cables inside.”
Commitment to Quality and Reliability
A core philosophy at Data Cable is an unwavering commitment to quality. The company prides itself on delivering highly reliable assemblies, ensuring that its products perform under demanding conditions. “Almost good is not good enough. It has to be right because someone is depending on it,” said Chelliah. He emphasized that the company’s wire harnesses are often part of mission-critical systems, whether for military or advanced medical equipment. “A defective cable in a half-million-dollar cancer research machine could mean bad data, and that’s unacceptable. Likewise, in the defense sector, a failed connection could be catastrophic. We take our role in these industries very seriously.”
To reinforce this mission, Data Cable maintains a culture of quality among its workforce. Employees are frequently reminded of the significance of their work. “In some areas of our plant, you’ll see a soldier’s photo with the caption: ‘Remember, everything you do affects this soldier.’ It’s a way to keep awareness high and ensure our associates understand the impact of what they do.”
Workforce and Knowledge Retention
The company operates with a workforce of 65 to 70 associates in a 35,000 ft² facility. The workforce number fluctuates based on demand. Temporary workers are occasionally brought in to handle surges in customer orders. “We are fortunate to have a highly skilled and tenured workforce,” Chelliah noted. “At least ten of our employees have been with us for over 30 years, and a few have reached 35-plus years of service. That level of experience is invaluable.”
Recognizing the risk of losing institutional knowledge as veteran employees retire, Data Cable has invested in knowledge transfer initiatives. “We ensure cross-training happens at every level so that skills aren’t lost when an experienced worker leaves. We also maintain thorough documentation, including digital archives of older designs. Some of our customers come back asking for cable assemblies we built in 2001, and thanks to our digitization efforts, we can still find the details.”
Embracing Automation and Efficiency
While Data Cable specializes in custom-built wire harnesses, the company has embraced automation where possible. “We have a fully automated wire processing unit that takes material from spool to crimp stage,” Chelliah explained. “Beyond that, a lot of manual work is still required because wire harness assembly often involves complex, hands-on processes. However, we continue to introduce semi-automated solutions for repetitive tasks like wire preparation.”
The company is also expanding its capabilities with new technologies. Recently, it invested in an overmolding machine, which allows for the production of ruggedized cable assemblies in-house. “Previously, customers had to send assemblies elsewhere for overmolding. Now, we can offer a full one-stop solution. Our top clients are excited about this because it simplifies their supply chain.”
Another area of innovation is transitioning from paper documentation to tablet-based work instructions. “This move ensures consistency and prevents information loss. Instead of handwritten notes that may not be understood by the next operator, everything is stored digitally and can be accessed in real-time by our engineering team.”
Market Positioning and Future Growth
While Data Cable does not actively pursue traditional automotive work, the company has explored opportunities in specialty vehicle markets. “We’ve built harnesses for large snowplows, mining trucks, and specialty heavy equipment. I attended the Automotive Wire Harness Conference to explore new opportunities, and we’re in discussions with several potential customers,” Chelliah explained. “We’re particularly interested in the aftermarket and legacy support sectors. Some OEMs need harnesses for discontinued models or service parts, and we can help with that.”
Looking ahead, Data Cable aims to achieve AS9100D certification to enter the aerospace market. “We are already ISO 9001-2015 certified, but AS9100D will allow us to manufacture for aviation applications. That’s a big step forward for us.”
Additionally, the company is investigating ways to semi-automate certain assembly processes. “We’re collaborating with a research institution to integrate cobots—collaborative robots—into some of our repetitive operations. This isn’t about replacing workers; it’s about improving efficiency and maintaining competitiveness.”
Competing on Quality, Not Price
Chelliah acknowledged that cost pressures are increasing, as some competitors move production to lower-cost regions like Mexico. However, Data Cable remains confident in its value proposition. “We don’t compete on price alone. Our customers come to us because of our quality and engineering support. In some cases, they may find a cheaper supplier, but they often return because they realize that cutting corners on something as critical as a wire harness isn’t worth the risk.”
One of Data Cable’s key differentiators is its ability to assist customers with engineering and design. “We don’t just take a bill of materials and build to spec. Many of our clients, especially those dealing with legacy products, come to us without proper documentation. We reverse-engineer solutions for them, suggest modern alternatives for obsolete components, and work closely to ensure they get the best possible product. That kind of support is something many competitors simply don’t offer.”
Expanding into the U.S. Market
A major growth initiative for Data Cable is expanding its presence in the U.S. “We’re located just a two-hour drive from Buffalo, so logistically, we are well-positioned to serve American customers,” Chelliah noted. “We comply with North American content requirements, and our exchange rate makes us a cost-effective choice. Many of our raw materials are already sourced from U.S. suppliers, so there’s no concern about tariffs when shipping completed assemblies back across the border.”
The company’s certifications also make it an attractive option for defense and high-security applications. “We are RoHS compliant, CSA certified, and UL certified. Additionally, we operate as a Canadian Controlled Goods Facility*, which means we are authorized to handle sensitive military and defense-related projects under Canadian government regulations. This certification ensures we meet strict security and compliance standards, making us a trusted partner for defense manufacturers.”
As Data Cable moves into its next phase of growth, its focus remains on quality, innovation, and customer collaboration. “We’re not looking to be the biggest player in the industry,” Chelliah concluded. “But we do want to be the best at what we do.”
If you would like to learn more about Data Cable, for any inquires, you can contact them at [email protected] or check their website www.datacable.ca to learn more.
- A Canadian Controlled Goods Facility is a secure, government-authorized site that complies with Canada’s Controlled Goods Program (CGP), regulating the examination, possession, and transfer of sensitive military, defense, and strategic assets to prevent unauthorized access and safeguard national security.
Many thanks to Courtney Steeves, Marketing Coordinator, for assisting with organizing the meeting and helping to fill in some details about Data Cable Company.
