An automated wire insertion machine for inserting wires into grommet cavity locations of an electrical connector includes a controllable wire insertion robot and a processor to generate pre-generated plug maps based upon an original plug map of the grommet cavity locations and to control the wire insertion robot based upon one pre-generated plug map to insert the wires into the grommet cavity locations. The pre-generated plug maps are generated by defining a range of potential error of the grommet cavity locations that includes at least one of a potential rotational error and a potential translational error, defining an acceptable tolerance of the grommet cavity locations that includes at least one of an acceptable rotational tolerance and an acceptable translational tolerance, and calculating offset values of the grommet cavity locations based on the range of potential error and the acceptable tolerance, thereby generating the plurality of pre-generated plug maps.