Suppliers and Exporters of Wiring Harness, Computer Accessories, Television Wiring Harness, Power Joints.

1. POPULAR SYSTEMS
An ISO 9001: 2008, ISO 14001:2004 and OSHAS 18001:2007
Certified Organization
The following profile will provide a brief introduction of our
Company, Products dealt, Quality systems and infrastructure.
We are looking forward to partner you in all related endeavors.
K.Vijaya Prabhu B.E.M.B.A
03/01/2014

2. TABLE OF CONTENTS
COMPANY PROFILE
PRODUCT DETAILS
FACILITIES
QUALITY
RAW MATERIALS AND PROCESS CONTROL
COMPETITIVENESS
CERTIFICATIONS
CONTACT DETAILS

3. POPULAR SYSTEMS
(An ISO 9001: 2008, ISO 14001:2004 and OSHAS 18001:2007 Certified Organization)
COMPANY PROFILE
he primary objective of POPULAR SYSTEMS is to manufacture high quality Assembly
wiring harnesses. The main agenda of the company since inception has been to provide its
customers with world class products at competitive prices and fortify consumer trust.
Our commitment to the Focused Factory (Synchronous Manufacturing) concept has allowed us to
streamline manufacturing in many ways, including better workflow, improved material handling, reduced
inventory and better utilization of floor space.
Our diverse manufacturing capabilities include Wiring harness panel assemblies and Wiring
Accessories. We are capable of providing prototypes of low- to high- volume production of simple to
complex harnesses. We provide 100% electrical testing on all assemblies. Our "full-service" capabilities
can be tailored specifically to you, our customer.
Our commitment to Total Quality Management is supported by strategic planning, process
analysis and implementation. From the moment RFQ is received, a cross-functional team is dedicated to
needs from product definition, through launch and on to program assessment where we identify
opportunities for continuous improvement
Table of Contents
T

4. PRODUCT DETAILS
Wiring Harness
We provide a wide range of high quality Wiring Harness that is manufactured
from the optimum quality raw materials. Wiring harness provided by us is available in
various sizes, dimensions and colors to meet the varied requisites of the clients. Our
wiring harness is widely used in various industries like automobile, electronics and many
others. Our wiring harness like Engine wiring harness, Electric Wiring Harness etc. are
highly durable and can endure high wear and tear.We have carved a niche as one of the
distinguished Wiring Harness Manufacturers and Suppliers, based in India.
Automobile Wiring Harness
Elevator & Escalator Wiring harness
Control Panel Wiring Harness
Electronic Control Device Wiring Harness
Wiring harness for Renewable energy (Wind Energy)
Home Appliances Wiring harness
Medical equipment Wiring harness
Data Cables
Wiring Accessories
Cable Ties
Wiring Harness Clips
Cable Glands
Wire Conduits
Heat Shrink Sleeves
Expandable sleeves
Spiral Conduits
Cable markers
Table of Contents

5. Automobile Wiring Harness
Popular Systems supports variety of OEMs as a contract manufacturer of Wiring harness.
We provide harnesses for various sectors of 2 wheeler and 4 wheelers like
1. Dash Boards
2. Horns
3. Melody maker
4. Head lamps
5. Steering control
6. Fuel pumps
7. Tank units
8. Complete Wiring harness for Electric Bikes
9. Two wheeler wiring harness of various standard bikes
10. Battery cables
Table of Contents
Product Details

6. Elevator & Escalator Wiring harness
We manufacture and supply Wiring harnesses of Car, Travelling cable harnesses
and control unit harnesses for Elevators. We supply emergency push button assemblies of
Escalators.
Table of Contents
Product Details

7. Control Panel Wiring Harness
Control panels of various applications such as T&D, Textile units, PLC
Controls require heavy quantity of pre assembled wiring. Popular Systems specialize in
this kind of wiring. We have in-house high quality printing facility for ferrules and heat
shrink tubes that are used in labeling. We use high quality press sleeve crimping for
superior quality terminations.
Table of Contents
Product Details

8. Electronic Control Device Wiring Harness
We provide wiring harness for Electronic control devices and PLC units that are
used to transmit signals to various parts of the control units. Our wiring harnesses stand
as an interface between sensors of various parameters and control devices.
Table of Contents
Product Details

9. Wiring harness for Renewable energy (Wind Energy)
We supply Wiring harnesses for Wind energy OEMs. EPR cables are used in
Nacelle harnesses of the Wind mills. Our harnesses operate from -40 Deg C to 90 Deg C
temperatures. We manufacture and supply
1. Nacelle harnesses
2. LV Cables
3. Earthing Cables
4. Signal cables
5. HT terminations
6. Junction box assemblies for Wind Energy
7. Yaw Encoders and sensor assemblies
Table of Contents
Product Details

10. Home Appliances Wiring harness
Home appliances OEMs who are manufacturers of products such as Water heaters
are using wiring harnesses for easy completion of their equipment wiring. Neon lamps,
LEDs and other active parts are clubbed with wiring harness for flaw free wiring.
Table of Contents
Product Details

11. Medical equipment Wiring harness
High precision of connectivity and conductivity is required for medical
applications. We use superior quality connectors from reputed manufacturers for all types
of our medical equipment requirements. Gold plated terminals are used for better
conductivity through frictional contacts.
Table of Contents
Product Details

12. Data Cables
Data Cables such as RJ485 Jack connector cables, TYPE A & B USB
Cables, FRC Connectors and Flat Cables are supplied from POPULAR SYSTEMS for
OEM and replacement market requirements.
Table of Contents
Product Details

13. Wiring Accessories
We provide complete support to OEMs for all types of accessories that are used to
mount our cable harnesses to their equipments. We are tied up with global manufacturers
like Hellerman Tayton and many Indian manufacturers for high quality and precision
products.
Cable Ties & Mounts
Cable ties provide mechanical support for the cable assemblies that are wired in
the equipments. Cable ties along with mounts provide flexibility for branching the cables
in panel boards.
Table of Contents
Product Details

14. Wiring Harness Clips
Used in mounting Wiring harnesses in automotive parts.
Cable Glands
Cable glands are mechanical cable entry devices and can be constructed from
metallic or non-metallic materials. They are used throughout a number of industries in
conjunction with cable and wiring used in electrical instrumentation and automation
systems. Cable glands may be used on all types of electrical power, control,
instrumentation, data and telecommunications cables. They are used as a sealing and
termination device to ensure that the characteristics of the enclosure which the cable
enters can be maintained adequately.

15. Wire Conduits
Corrugated Flexible Tubes also known as Cot Tubes / Convoluted Conduits have
a wide range of application for harnessing cables in:
• Automobiles: HCVs / LCVs / Four Wheelers / Two Wheelers
• Electrical Control Panels
• Home Appliances: Washing Machines / Fridges
• Railway Coaches
• Aircrafts
• Ships, etc.
Heat Shrink Sleeves
Heat-shrinkable sleeve (or commonly "shrink sleeve") is a corrosion protective
coating for pipelines in the form of a wraparound or tubular sleeve that is field-applied.
We provide Heat Shrinkable sleeves & Tubes of various dimensions and all colors. We
support for adhesive lined heat shrink sleeves also.
Table of Contents
Product Details

16. Expandable sleeves
Expandable braided sleeving is a protective self fitting oversleeve that protects
your cables and wire harnesses from hostile environments. We use “Fray Free” thermal
cutting system for expandable sleeves. We can also support expandable sleeves of all
standard sizes and colors.
Table of Contents
Product Details

17. Spiral Conduits
No cable can meet the demands posed today in terms of abrasion resistance,
tensile strength and form consistency or impact resistance without having appropriate
cable protection. Cable protection tubes (flexible conduits, braided sleeving, spiral
binding) have to meet these demands and also provide protection against dirt and
dampness or resistance against extreme temperature loads.
Table of Contents
Product Details

18. Cable markers
We have in house printing facility for printing PVC tubes, Heat Shrink
sleeves and Cable identification ferrules. We use high quality non erasable thermal
transfer printing technology for all types of cable markers. We support labeling and bar-
coding of cable assemblies also.
Table of Contents
Product Details

19. FACILITIES
MACHINERIES
Fully Automatic Wire Cutting striping and crimping machine
Wire cutting and stripping machine
Multi core cable Cutting and de-sheathing machine
Pneumatic core stripper
Wire cutting stripping and twisting machine
Microprocessor based Battery cable Cutting Machine
Pneumatic Cable outer jacket removal machine
Pneumatic Crimping machine for Scattered terminals
Semi automatic crimping machines
Electronic Crimping Presses
Applicators
Toggle crimping machines
Wire stripping and twisting machines
Soldering station
Coupler assembly station
Air Compressor ( 3 Hp and 5 Hp)
25 KVA Generator
Microprocessor based Harness tester (1024 POINTS AND 64 POINTS)
Table of Contents
Product Details

20. QUALITY
We are an IMS (ISO 9001:2008 , ISO 14001 and OSHAS 18001) firm.
POPULAR SYSTEMS invests heavily on testing procedures and protocols to ensure trouble free,
reliable outputs. We have a mating inspection section, coupler seating position-inspection section and
harness tester to ensure high quality delivery. We do 100% electrical testing for upto 1024 point harnesses.
Systems implemented
Statistical Quality Control - SQC with Cp ,Cpk Validation for Crimping
5 Systems
Total Productivity Management - TPM
5 Why Analysis & 8D for Logical interference
Shop Floor Control
Table of Contents
Product Details

21. RAW MATERIALS & PROCESS CONTROL
Raw Materials Used For Production:
We use Lapp (Single/Multi core) cables, armored cables, Shielded cables and also PVC wires for
manufacture of our harnesses.
We use imported connectors such as Sumitomo, Tyco, Berg and Molex for specific applications of
our customers. We also have good tie-ups with best manufacturers of couplers and terminals in India.
Process Control
Our process is completely controlled with records. Critical process like crimping are controlled
with charts. Machine consistency is ensured by evaluation of Cp and Cpk .Final product is bar-coded for
better traceability.
Production Capacity
We make around Five million crimps per month and we have ambitious expansion plans to make
around Ten million crimps per month.
STRENGTHS
1. JIT Assembly Line
2. Single Piece Flow Manufacturing System
3. Employee Involvement at all levels
4. Flexible Production Planning System
5. Un-paralleled Customer Service
6. Good Business Practices and Good Manufacturing Practices at all
Levels
7. Complete Transparency with our customers
Table of Contents
Product Details

22. COMPETITIVENESS…
We maintain competitiveness with the following steps
•Procurement of Raw Materials from the most cost effective sources,
•Keeping the Least Inventory.
•Adoption of the best process to increase Productivity to the optimum level.
•Adoption of the latest Techniques,
•Value Engineering as a Continuous Process
•Keeping the Overheads to the Essentials with Minimum level
•Best utilization of Machinery, Man Power, Space, Power, etc., to gain the maximum efficiency.
•Best Quality product with competitive price.
•100% acceptance with customers (Zero defects)
All the products manufactured cater to the specific requirements of the clients. We manufacture products
according to the International Standards. Our performance and commitment are the key for our success.
We make sure that people's roles are clear and that they are held accountable for their actions and
believe in absolute honesty and transparency in our dealings with our clients and business associates.
Table of Contents
Product Details

23. CERTIFICATIONS
We are an ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 (IMS) Certified organization
AWARDS & ACCOLADES
BEST SUPPLIER 2013 – GAMESA WIND TURBINES
GLOBAL ACHEIVERS AWARD FOR BUSINESS LEADERSHIP 2013 – ECONOMIC
DEVELOPMENT FORUM (INDIA)
Table of Contents
Product Details
THANK YOU

24. CONTACT DETAILS
K.VIJAYA PRABHU B.E., M.B.A.
Proprietor
POPULAR SYSTEMS
(An ISO 9001: 2008, ISO 14001:2004 and OSHAS 18001:2007 certified Organization)
Office Address:
77 A,Mariamman Koil Street,
Narasimhanaickenpalayam,
Coimbatore-641031
Tamil Nadu, India.
Mobile:+91-9894623369
+91-7812048123
Phone:+91-422-2462372
Fax:+91-422-2462471
Email :
info@popularsystems.net
popularsystems@yahoo.co.in
sales@popularsystems.net
Website: http://www.popularsystems.net/
http://www.popularsystems.in/
COMMERCIAL DETAILS
TIN NO: 33182025595
CST NO: 859250 DATED: 16/9/2005
ECC NO: AMBPK 2864 KXM 001
IEC NO: 3206019478
NAME OF THE BANKER: ICICI BANK, PERIANAICKENPALAYAM
ACCOUNT NO: 003305001083
RTGS/NEFT/IFSC CODE: ICIC0000033
MICR NO: 641229003
USD ACCOUNT:
a) Routing Bank: Pay to: JP Morgan Chase Bank, USA
b) SWIFT code: CHASUS33XXX
c) Further credit to: ICICI BANK LTD holding account no:001 1 427374
d) ICICI Bank swift Code: ICICINBBCTS
e) Final credit to: ACCOUNT NO:001605009926
ACCOUNT NAME: POPULAR SYSTEMS
Table of Contents
Product Details