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Reducing Risk in Your Custom Cable Assembly

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Introducing new designs in your project always incurs some element of risk, and this is especially true when it comes to custom cable assemblies. Some of the most common cable assembly issues include long lead times, poor quality, and undesirable performance.

With proper planning, and a clear understanding of the options available, both engineers and buyers can develop risk reduction plans to ease the impact of issues that may arise during development and manufacturing.

In this webinar we review the risks and offer ways on how to reduce those risks in your custom cable assembly.

For more information on our cable assembly solutions visit https://www.epectec.com/cable-assemblies/.

Published in: Engineering
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Reducing Risk in Your Custom Cable Assembly

  1. 1. Manufacturing That Eliminates Risk & Improves Reliability Reducing Risk in Your Custom Cable Assembly 11.20.20
  2. 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. 3. Manufacturing That Eliminates Risk & Improves Reliability 3 What is Risk for Your Custom Cable?
  4. 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. 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. 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. 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. 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. 9. Manufacturing That Eliminates Risk & Improves Reliability 9 Managing Risk for Your Custom Cable
  10. 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. 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. 12. Manufacturing That Eliminates Risk & Improves Reliability 12 Design Options to Reduce Risk
  13. 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. 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. 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. 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. 17. Manufacturing That Eliminates Risk & Improves Reliability 17 Case Studies: Charging Cables
  18. 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. 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. 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. 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. 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. 23. Manufacturing That Eliminates Risk & Improves Reliability 23 How To Get Started With Your Custom Build
  24. 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. 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. 26. Manufacturing That Eliminates Risk & Improves Reliability 26 Summary
  27. 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. 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. 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. 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:

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