Reducing Risk in Your Custom Cable Assembly

1. Manufacturing That Eliminates Risk & Improves Reliability Reducing Risk in Your Custom Cable Assembly 11.20.20

2. Manufacturing That Eliminates Risk & Improves Reliability 2 Agenda  What is Risk for Your Custom Cable?  Managing Risk for Your Custom Cable  Design Options to Reduce Risk  Case Studies: Charging Cables  How To Get Started With Your Custom Build  Summary

3. Manufacturing That Eliminates Risk & Improves Reliability 3 What is Risk for Your Custom Cable?

4. Manufacturing That Eliminates Risk & Improves Reliability 4 What is Risk?  Wikipedia – Risk is the possibility of something bad happening.  Risk often focuses on negative, undesirable consequences.  What is the Business Risk Impact?  Types of Risk for Custom Cable Assemblies – Design – Cost – Sourcing

5. Manufacturing That Eliminates Risk & Improves Reliability 5 What is Risk for your Custom Cable?  Inadequate design or assembly process  Shipment and handling logistics  Overmold tooling rework  Component end of life / obsolescence  Delays with design approval  Supplier’s Going Concerns  Quality and workmanship concerns  Long lead-time materials  The connectors don’t mate properly  Tariffs or import duties  Qualification test failure  Material incompatibility Risk Cannot be Eliminated- Only Managed

6. Manufacturing That Eliminates Risk & Improves Reliability 6 Types of Risk- Design Risk  Design Risk – The inability for hardware to satisfy program objectives.  Requirements Change – Scope creep – Customer driven changes  Design / Assembly Error – Wrong pinout – Improper crimp / solder connection  Insufficient Performance – Connector will not meet the performance goals – Incompatible materials Design Reviews and In-Process Inspection are vital

7. Manufacturing That Eliminates Risk & Improves Reliability 7 Types of Risk- Cost Risk  Cost Risk – The risk that the project costs more than originally budgeted.  Materials Cost – Purchase parts – Raw materials  Minimum Buy – Lot charges – Minimum order qty (MOQ)  Quotation Error – Bid assumptions – Incomplete documentation Advanced planning helps manage the impact

8. Manufacturing That Eliminates Risk & Improves Reliability 8 Types of Risk- Sourcing Risk  Sourcing Risk – Disruptions to supply chain logistics and input materials.  Sourcing Logistics – Shipment and transit – Ramp up time  Reliance on 3rd Parties – Stocking distributors – Immature infrastructure  Free Trade Agreements – Tariff and import duties – Country of origin An understanding of the Supply Chain helps manage risks

9. Manufacturing That Eliminates Risk & Improves Reliability 9 Managing Risk for Your Custom Cable

10. Manufacturing That Eliminates Risk & Improves Reliability 10 Managing Risk- Quotation  Is the quote documentation clear?  Does the quote match the scope of work required?  Tooling, NRE, Engineering Fees  Tariffs

11. Manufacturing That Eliminates Risk & Improves Reliability 11 Managing Risk- Design Freeze  Require a drawing  Include a pinout  Design for manufacturability  Document testing specifications

12. Manufacturing That Eliminates Risk & Improves Reliability 12 Design Options to Reduce Risk

13. Manufacturing That Eliminates Risk & Improves Reliability 13 Design Steps to Reduce Risk  Single Conductor vs. Multiconductor Cables  Risk Analysis – Many multiconductor extrusions are custom  Impact – Long lead-time – Minimum buys  Guidance – Use single conductor cables for protypes – Invest in extruded cable once the design is finalized Custom Multiconductor Cable Single Wires Bundled

14. Manufacturing That Eliminates Risk & Improves Reliability 14 Design Steps to Reduce Risk  House Tooling  Risk Analysis – Custom tooling can be expensive – Modifications will impact the timeline  Impact – Tooling can cost $1K - $12K – 2 – 6 weeks for modifications  Guidance – Consider common connector schemes – Is a custom overmold required? Customer Supplied Sample Epec House Tooling M12 x 4 Pin Connector

15. Manufacturing That Eliminates Risk & Improves Reliability 15 Design Steps to Reduce Risk  Incompatible Materials  Risk Analysis – Will the overmold bond to the wire jacket? – Do you require a standard material?  Impact – Failures during leak testing – Material minimum buys  Guidance – Specify test requirements early – Consider materials like PVC or TPE IP67 Seal Required Material A: Wire Jacket Material B: Overmold

16. Manufacturing That Eliminates Risk & Improves Reliability 16 Design Steps to Reduce Risk  Detailed Manufacturing Processes  Risk Analysis – Process variations will impact function – Tooling is required for assembly  Impact – Water ingress – Tooling leadtimes and cost can vary – Some crimp tools are non-stocked  Guidance – Document complex assembly steps – Review all tooling required in advance Crimp Tooling RTV Squeezeout

17. Manufacturing That Eliminates Risk & Improves Reliability 17 Case Studies: Charging Cables

18. Manufacturing That Eliminates Risk & Improves Reliability 18 Charging Cable- Case Study #1  Children's Nightlight  120VAC Wall Outlet  Micro-USB  Low Voltage LEDs  Use House Tooling – Readily Available – No NRE Cost Micro-USB Plug Overmold Mating Connector

19. Manufacturing That Eliminates Risk & Improves Reliability 19 Charging Cable- Case Study #1  $0 NRE Tooling  5 weeks total: From quote request to shipment  No detailed design for the overmold USB house tooling- readily available and with zero cost

20. Manufacturing That Eliminates Risk & Improves Reliability 20  Beard Trimmer  120VAC Wall Outlet  Custom two-pin connector  Small electric motor  Inner & outer overmold – Add “+” “-” – Splashproof  Mating connector is custom – 2x connector designs Charging Cable- Case Study #2 Polarization Markings Power Cable Overmold 2-pin Mating Connector

21. Manufacturing That Eliminates Risk & Improves Reliability 21 Charging Cable- Case Study #2  $5000 NRE Tooling  8 weeks total: quote request to shipment  Will require both male and female connector designs Customization is possible- but adds time and cost

22. Manufacturing That Eliminates Risk & Improves Reliability 22 Case Study Comparison  Uses readily available tooling  $0 NRE  5 weeks development  Overall Risk: LOW  Numerous custom tools  $5000 NRE  8 weeks development  Overall Risk: MEDIUM Customization can add +3 weeks and additional NRE

23. Manufacturing That Eliminates Risk & Improves Reliability 23 How To Get Started With Your Custom Build

24. Manufacturing That Eliminates Risk & Improves Reliability 24 Development Timeline Production tooling typically requires 2 - 6 weeks Proof of Concept 3D Model Samples Fit Check Production Typical Tooling Lead-Times House Tooling 0-2 weeks Simple Tooling 2-4 weeks Complex Tooling 4-8 weeks

25. Manufacturing That Eliminates Risk & Improves Reliability 25 Epec Inquiry Form  When starting a project with Epec, we ask if you could please fill out our Inquiry Form.  This allows us to capture all the information of your design upfront, eliminating guess work.  Also allows us to provide you with an accurate quote.

26. Manufacturing That Eliminates Risk & Improves Reliability 26 Summary

27. Manufacturing That Eliminates Risk & Improves Reliability 27 Summary  Risk cannot be eliminated, only managed.  Focus on design, cost, and sourcing risk.  Manage risk at the quoting and design freeze stages.  Plan for design for manufacturability reviews.  When cost and timelines are tight, use existing designs.

28. Manufacturing That Eliminates Risk & Improves Reliability 28 Our Products Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards RF Products User Interfaces Flexible Heaters EC Fans & Motors

29. Manufacturing That Eliminates Risk & Improves Reliability 29 Q&A  Questions? – Enter any questions you may have in the Control Panel – If we don’t have time to get to it, we will reply via email

30. Manufacturing That Eliminates Risk & Improves Reliability 30 Thank You Check out our website at www.epectec.com. For more information email sales@epectec.com. Stay Connected with Epec Engineered Technologies Follow us on our social media sites for continuous technical updates and information: