WireProcess Specialties

Counting the Cost of Quality: The Cost of Inaction

December 12, 2016 wireprocess Application Illustrations, General-Business-Commentary Comments Off

Every Decision has a cost.

Continuing the series Counting the Cost of Quality, we turn from the Cost of Action in Part One to the Cost of Inaction.

So what happens when you do not act? Maintain the status quo. I acknowledge that there are some times in a company’s history when a short term “pause” is needed. Due to uncertain economics or other external conditions. This is different from big picture inaction. In the case of quality, there is no time that a company should pause from improving quality, quality systems or understanding the changing dynamics of quality processes.

… there is no time that a company should pause from improving quality, quality systems or understanding the changing dynamics of quality processes.

In the end all decisions to act or not rest with management. And the implications of the decision (or non decision). Here are a few possible considerations and implications of not acting.

First, not taking the step of understanding the changes in quality processes and the standards that industries are using to validate and monitor quality. This can be as damaging as knowing and not acting.

Some industries are leaders in quality. And what they adopt often become best practices which other industries adopt in whole or in part. They were created for a reason. Not investigating new practices and reviewing the potential use in your organization can be a lost opportunity to become a leader in your industry. For example the Automobile Industry are widely using cross section analysis to validate, monitor and improve quality of connector crimping. With the cost of these systems coming down, it makes sense for non-automotive companies to start adopting cross section analysis.

Not investigating new practices and reviewing the potential use in your organization can be a lost opportunity to become a leader in your industry.

What if your competitor seized the opportunity to implement new quality processes? And their quality improved when they used these new tools. And they broadly publish their new capability to the world. Prompting companies (including your customers) to take notice. You are at a strategic disadvantage when your competitor gets a jump on your company.

You are at a strategic disadvantage when your competitor gets a jump on your company.

Inaction due to the cost of processing tools, systems and training ignores the long term benefit from reduced cost of processing. Scrap and rework costs can eat into profitability. A focus on quality improvement can also help to improve production efficiency.

Employees are watching. Engaging personnel in the process of quality improvement can be positive and beneficial. But when personnel see management not acting, they soon follow and productivity declines. Personnel on the factory floor are looking for individual benefit in the case of working conditions and some level of assurance the company is going all out in their efforts to maintain and grow the business.

Customers are also watching. With domestic and international competitors on your customer’s doorstep, can you afford to not consider new quality systems? And implement them into the company’s culture.

With domestic and international competitors on your customer’s doorstep, can you afford not to consider new quality systems?

Looking at the negative side of this topic is something companies do not enjoy doing. Simply put, ignoring the world changing around you or knowing and not acting is not a good business strategy. And can be damaging or fatal to a company in the long term.

The good news there is always an opportunity to turn the ship around, no matter how big the ship. Today would be a good day to seize the opportunity and start acting!

Global Technology Partners in Focus: Crimping and Stamping Technologies

November 9, 2016 wireprocess C&S Technologies, Product Focus Comments Off

There are watershed moments in a company’s history, times when a single decision can change the course of a business. Such is the case with WPS in the early 90’s. When we were looking to enhance our product offering with new product lines and technology, a brochure about crimp monitors arrived in the mail. The decision to inquire about this technology led to the start of a business relationship that exists to today. And which also led to two other significant connections in Schaefer Megomat and Stapla Ultrasonics.

I am pleased to introduce Chris LaRue. Chris is the President of Crimping and Stamping Technologies and one of the hardest working people in the wire processing industry.

WPS: Thank you for taking a few moments to speak to us today Chris. You have spent your career in crimp technology. Tell us a little about your background.

CL: I am a mechanical engineer by degree and started my career at Amp Connectors (Harrisburg PA) in 1984. I was a die engineer in Amp’s high speed stamping facility. I was the first engineer to be hired in the die engineering rotational program. This was a two-year training program with assignments in stamping, injection molding, plating and assembly.

After seven years at Amp, I had an opportunity to join a small start up company supplying stamping monitoring systems.

After a few years, I made the move to form C&S Technologies.

WPS: Can you provide a rundown of the product offering through C&S.

CL: C&S supplies solutions for validating and process monitoring for wire harness manufacturing.

WPS: Where are your facilities located.

CL: Our facilities are in Pittsburgh PA, Chihuahua Mexico, Juarez Mexico and Queretaro Mexico. Internationally we partner with True Soltec in Tokyo Japan. Also CTEC in Munich Germany.

WPS: Automotive assembly has driven advances in crimp quality technology. Although there are several advances in monitoring and validating the crimping process, can you highlight a few significant technology advances

CL: Crimp Cross Sectioning has been a crimp development tool for several years. But it has been limited to a lab environment. Now because of cost reduction, simplicity and speed these systems have found their way to the production floor as an additional set up validation and process monitoring tool.

With our pioneering efforts in the early 90’s, Crimp Force Monitors have become a core technology which is now widely used in wire processing. Required by Automotive and White Goods manufacturers.

Advances in electronics, software and wireless technology have made networking of production equipment in-expensive. And very powerful. Now you can retrieve real time data from any process, including crimping machines, ultrasonic welders, rotary assembly boards. To monitor and report machine up and down time, defects, production quantity to name few.

WPS: Do you see other industries following the Automotive lead and adopting new crimp quality technology

CL: White Goods is one industry that has seen significant improvement in the quality of their wiring systems due to them embracing new processing, harness designs and monitoring systems.

WPS: What do you see as an emerging technology in crimp technology.

CL: Crimp Cameras are now being mounted on automatic processing machines. What was not feasible ten years ago is now possible with the advanced electronics, software and camera technology. In the case of wire processing, high speed machines require ultra fast feedback to address defects such as high insulation, brush errors and deformed insulation crimp wings. We are on the cutting edge of this camera technology.

Thank you for your time today Chris. WPS values the association we have built up over the past two decades and anticipate helping our customers adopt new and emerging technology in wire. Thank you for your support.

Global Technology Partners in Focus: Schaefer Megomat

October 21, 2016 wireprocess Application Illustrations, Schaefer Megomat Comments Off

Schaefer Megomat has been part of the WireProcess Global Technology Partners Group for over 20 years. We have had a long and successful partnership in supplying wire processing solutions to our valued customers. And our customers have benefited by reducing their processing costs and improving their production efficiency in wire processing assembly.

We have seen a revolution in wire processing over the past 20 years or so. From pneumatic processing machines requiring time consuming set up to servo based systems incorporating advanced micro-processors and motion control. Set up time has been drastically reduced with the introduction of these advanced system technologies.

I am pleased to introduce Todd Miller of Schaefer Megomat. Todd is the Assistant General Manager of Schaefer Megomat and oversees the automation assembly operations out of Pewaukee Wisconsin, a suburb of Milwaukee.

WPS: Todd, thank you for speaking to us and to our WireProcess Global Community. How long have you served at Schaefer Megomat.

TM: Thank you for giving me the opportunity to talk with you today. I started my career here with Schaefer Megomat (or just Megomat at that time) back in 1997. I have been lucky enough to hold many different titles and positions through the course of my employment, with the most recent being the AGM since 2014. Growing up in this company has given me a unique perspective of what it takes to bring our customers a quality product from all sides of the business.

WPS: Schaefer Megomat is part of the Schaefer Group. Can you expand on the company’s operations and global product offering.

TM: The Schaefer Group purchased Megomat USA back in 2005. We feel this partnership gave us an instant global presence and added to the stability and variety of products and services that we are able to offer to our customers. With the acquisition, the Schaefer group can offer our customers everything from small hand held wire stripping devices, all the way up to multi-function, autonomous special machines designed specifically for a customer’s applications and needs. Some of the other products that Schaefer now offers include applicators, stripping and crimping modules, hot stamp marking, tinning, crimp quality monitoring systems, twisting, seal application units, injection molding, and even testing and laboratory equipment. Chances are if you are in the wire industry and have a need, we can help you!

WPS: As mentioned in the introduction, Schaefer Megomat is based in Pewaukee, Wisconsin. Can you describe the operation and activities at this location?

TM: Schaefer Megomat was started in 1990 to be a direct sales and service company for all the Megomat products. Over the years, as we gained market share, we faced the need to expand our operations and facilities. In 1995 we built a 30,000 square foot facility on 4 acres of land in Pewaukee, WI which has served as our North American base of operations ever since. We have added mechanical and electrical engineering ability over the years, so we are able to design, build, service and support all of our equipment from this location. We currently have 26 active assembly bays in-house, with the ability to add more as demand would dictate. Our facility also offers the space to hold thousands of parts, in stock, to assure our customers’ needs are always met. In addition, we have a sales and service location in El Paso, Texas as well to serve our customers in the south and Mexico.

WPS: How does Schaefer Megomat service their customer base domestically (in the United States) as well as Internationally (North America and beyond).

TM: Schaefer Megomat prides itself on our ability to service our customers and we rely on the small business customer service mantra that our customers have come to expect over the years. Even though we have grown with the Schaefer acquisition, we have never gotten too big to provide our customers with the personal level of service that they require and expect. We have many well trained service technicians based out of Wisconsin, El Paso, and around the world that insure the equipment we sell stays on-line and in production. Locations in Germany, Switzerland, Brazil, Mexico, Romania and Asia, to name a few, help to assure we can service what we sell, no matter where it is located.

WPS: What machine platforms are assembled at the Pewaukee facility?

TM: Our Pewaukee facility is currently home to the assembly of our fully automatic wire processing equipment line. We are now building the next generation of fully automatics using our recently updated WireStar20 software and electronics package. Our base model M500, newly updated 4-station M600, and flexible, 6-station capable M800 machine are all currently built in this facility. We have also recently started the production of select applicators in our Pewaukee facility as well to insure our customers can have a one-stop shop type experience for all of their wire applications.

WPS: How does the corporate Schaefer organization support the Schaefer Megomat operations?

TM: The Schaefer Group provides us with a global presence, technical and engineering resources, as well as adding additional expertise and real-world experience in many different areas of the industry. Thank you for talking with me Terry. Schaefer Megomat values the relationship we have built over the years with Wire Process Specialties.

Thank you Todd for your time today. For more information on Schaefer Megomat, please visit the Global Technology Page of www.WireProcess.com or www.Schaefer.biz.

Counting The Cost of Quality: The Cost of Action

September 18, 2016 wireprocess Application Illustrations, C&S Technologies, Uncategorized Comments Off

Every decision has a cost.

Large or small there is a cost to every decision. Of course there is a sliding scale of the size of a decision and it’s relationship to the overall implications to the organization. Some costs are economic and some are not. Deciding on a bathroom cleaner or brand of pencil to stock have fewer implications than a capital purchase or facility relocation.

This the first of three articles focused focused on quality and considerations when making improvements to an existing system or completely starting from scratch. Also the costs associated with these actions that have far reaching implications to product quality within a manufacturing environment. In this post we are focusing on the cost of action.

Here are a few point for consideration.

Management acts on quality improvement but there is usually a trigger. Triggers that cause management to act are either external or strategic. External triggers often come from customers who require improvement in quality either due to a complaint or issue. They are also driven by the customer’s desire to focus on a specific industry sector that demands higher quality standards. Strategic triggers are based on the company moving into a new industry sector which (like the customer) demands an enhanced quality or documentation of quality. Regardless of the trigger it all boils down to one thing: economics. Losing a key account or losing out on a new opportunity to grow the business in a new direction can greatly affect revenue which can affect the business partly in the short term but mainly in the long term.

Management not only needs to be fully committed to a new quality system, they need to be the champions of it. Often it is management that has a neutral or “wait and see” attitude. This can be damaging to the success of implementing a new quality system. Or the efforts to make permanent the change in culture. Employees are watching. When management waivers, employees often follow.

We will expand on the potential negative affects in part two: The Cost of Inaction.

Commitment includes attention to the following areas:

Employees need to be fully supported. In the form of solid two communication between management and employees. They need to understand the reasons behind the change or initiative. When communication breaks down so does the trust.

Employees also need appropriate training. The company needs to provide the funding for training (and re-training) for all workers directly (and indirectly) involved in quality.

Resources are critical to the success. These include measurement and in process monitoring tools for validating and monitoring production. Also access to applicable quality standards for your industry. These tools provide data necessary to feed back to management on the current state of the quality system. And levels of improvement over time. One important point. Providing new measurement tools is an important first step but often they uncover the current state of the quality system. They do not improve it. Training in conjunction with the above tools can provide the information needed to make the changes needed to drive quality improvements. But looping back to management’s commitment, they need to drive the changes needed (and the speed of change) and support the organization as a whole.

Capital Costs are important over the life of a quality improvement initiative. As information starts flowing on the current capability of the production system, it may become evident that production equipment over the long term is not capable of repeatable results of a higher quality level. Replacement production equipment or major upgrades to existing equipment will be necessary.

In summary, making a decision to improve quality comes at a cost. In the attitude of management and employees, a commitment to invest in the resources and the capital needed to make an improvement in product quality. There is also a cost of inaction which we will cover in part two. And the benefits? Part three will uncover the reasons why sticking it out to the end will be critical to the company’s survival in rapidly changing business conditions.

You Asked: “When should we automate?”

September 5, 2016 wireprocess Application Illustrations, Schaefer Megomat Comments Off

Automation is a big step most manufacturing companies consider at one point in time. There are a distinct advantages which include improved quality and more accurate piece to piece consistency.

This question to automate is frequently asked. Is there a trigger that pushes you to make a decision to invest in automation? Are there signs leading to that decision? We will address these topics in this post. First a short answer and following some points to consider.

The short answer is no. There are no defined rules to move you into automation. Every company and their business conditions are different. Some will move quicker to automate while others integrate automation much slower. Volume per batch is less of a consideration. Annual production volume is a greater consideration.

There is a sliding scale to automation. In general, any production above manual hand tool processing can be considered automation. For a perspective on a migration path from manual to automated processing, consider Methods of Processing Wire Assemblies. For the basis of our discussion, we are focusing on the migration from semi automating processing of wire (measure, cut and strip using single or multi-stage bench top machines) to an automated work center.

Elements of wire processing automation

The most basic of processing automation is the measure, cut and strip of wire and crimp of terminals on one or both ends. But automation allows for other processing possibilities. Typical secondary processing options include:

Tin tipping of wire
Ultrasonic tipping of wire
Weather seal application.
Wire doubling.

Ultrasonic wire tipping

Weather Seal Application

Current or future processing should include an evaluation of processing wire leads using the above secondary processing. This makes justification easier to achieve and gives the company an indication of the scope of machine solution needed.

Set up time and job lot sizes.

In the past, automation was justified based on one or several large production runs. That was due to the time it took to change from one set up to the next. Pneumatic motions and bolted in production tooling gave way to programmable servo motors and quick change tooling bases. Therefore it is easier to run smaller lots with less machine down time than in the past.

With production rates in excess of 3,000 pieces per hour on short wire lengths, there still needs to be a reasonable lot size. Providing a recommended lot size would not be useful as companies consider a range of minimum lot sizes. You just need to balance the set up time with the lot size and the acceptable number of set ups per day.

Labor Savings.

There is a potential for significant labor savings when moving to automation. But consider that the personnel that operate the automation systems need to be trained in the machine operations, the software and use of a micro processor communication interface. Also consider maintenance resources.

Conditions Triggering a move to Automation.

Typically there are two conditions that we see when companies migrate to automation.

Business Growth. This is a slower movement towards the point where the decision to automate occurs. Available resources in capital funding, facility floor space space and the need to reduce direct labor content will converge to make a seamless decision to automate.
New Contract. When the company receives a substantial contract for a specified duration, the decision is quicker.

Floor space can be a factor that speeds up or slows down the decision to automate. Limitation of floor space to accommodate the new machine installation can be an issue. Re-locating to a larger facility may be part of a larger business strategy that includes new automation investment. Often it is a balance between the distribution of labor, overall direct labor costs and the availability of floor space.

Summary.

As stated from the beginning, automation is a big step in any company large or small. Considering global annual production of wire assemblies that are processed is more important than large lot sizes due to the reduced set up time with newer technology processing machines. Redeployment of labor, training personnel in set up operation and maintenance are critical factors. Where a decision to automate is made from a new large volume contract, the duration of the contract is also an important factor.

When these elements are considered and in conjunction with good advice from outside sources, the migration to automation is a low risk proposition. WireProcess can provide the direction you need and the solutions required to fulfill your automation requirements. Connect Your Way to WireProcess.

Crimp Force Monitors Do Not Solve Your Crimping Problems

August 31, 2016 wireprocess Application Illustrations, C&S Technologies Comments Off

There I said it. Let me repeat:

Crimp Force Monitors Do Not Solve your Quality Problems.

Now that it’s out there let’s back up a little. First of all, let me be crystal clear. Crimp Force Monitors (CFM) are an essential tool of a quality system for any company that is serious about providing quality wire assemblies. The ability to monitor your process with a crimp monitor is extremely valuable for a number of reasons which we will unpack in this article. But let’s put things into their proper perspective.

First of all, a crimp process that has excess variation exists that way with or without a CFM. A CFM does not resolve crimp problems but will provide plenty of notification to the operator of this condition. In the form of CFM alarms. It is what is done from this point that is critical. If the tolerance is opened up to silence the alarms or (worse) the monitor is turned off, then the true value of the CFM is lost.

Second, a CFM works best with a process that is in control and shows little piece to piece variation. This provides sufficient room for detecting small defects in the crimp process. Excess variation adds “noise” to the detection process and a CFM will have a harder time in determining a defect or just normal process variation.

The video below is from the 2016 Electrical Wire Processing Technology Expo and the seminar co-sponsored by C&S Technologies and Applitek Technologies: Do You Really Know Your Crimp Process where we discuss the CFM Cycle, a scenario played out countless times as new CFM Technology is introduced.

So what value is a CFM in the crimping process?

First, real time monitoring is 100% effective in measuring the crimp process. Visual inspection is only 80% effective over time and 100% manual inspection is not practical. It also answers the question: “what is happening between the first off article inspection and spot in process inspection”.

Second, as a process analysis tool, a CFM is effective in improving the crimp process over time. This is done by analyzing the five elements of a terminal crimp. And improving each process. The direct effect is a process in greater control and able to detect smaller variation.

Finally, as part of an integrated network of processing machines, the CFM can feed valuable production quality data into a central database for archival and analysis. Also provide a level of production quality approval by preventing access to production equipment until quality measurements are within allowable parameters.

So the question is “Do you need a CFM equipped facility?” Consider the following and judge for yourself.

Pull test and crimp height measurements are a static and one-time check of quality parameters. As important as they are to production quality, they are not sufficient in of themselves. A CFM is one example of dynamic quality measurement in real time. Press Analysis is another example of dynamic measurement.
CFM’s remove subjective judgement of good or bad crimps from employees.
CFM’s monitor the whole crimp process and the associated elements.
Without crimp monitors, the risk of defective wire harnesses increases and the cost of rework (not to mention product liability) will exceed the initial investment of crimp monitor technology by a large margin. “It hasn’t happened to us so far” you may say. “We have crimped millions of parts over the years with no problem” is another one. The laws of probability will eventually catch up without effective dynamic crimp monitoring. Why take the risk?

Do not take the risk! Our Global Technology Partner: Crimping and Stamping Technologies is a global authority in the terminal crimp process. Connect Your Way to WPS for an analysis of your crimp quality requirements.

Global Technology Partners in Focus: Lakes Precision

August 8, 2016 wireprocess Application Illustrations, Lakes Precision Comments Off

We continue our Focus series with an interaction with long time partner Lakes Precision. Lakes has a long and proud history of serving the Global Wire Processing Industry with high quality replacement tooling for wire cutting and stripping machines as well as terminal applicators. I am pleased to present Rich Javenkoski VP of Sales for Lakes Precision.

WPS: Thank you for spending some time with us Rich. Give us a little background on the history of Lakes, how long Lakes has been serving their customers and where the headquarters is located.

RJ: Lakes Precision Inc as we know it today started in 1991. Using technology that allowed high production, high precision manufacturing we are able to meet the requirements of our customers. Not only in quality, but cost, and the high volume demands of global harness manufacturers. Lakes Precision has a sales and service office in El Paso TX for Mexico, Central America, and parts of South America. Our global network provides localized representation with the ability to stock inventory and needed technical assistance. With an ever changing global environment, our staff is dedicated to insuring we provide the highest quantity tooling to any global location.

WPS: Lakes has been associated with a number of OEM machine manufacturers over the years. Has this helped in the development of the Lakes blades?

RJ: Yes It helps in the sense that we understand the dimensional specifications needed for any OEM blade. We then can take that knowledge and transfer it in our manufacturing processes. Further this helps when developing custom products or unique blades not offered by the OEM’s. In some instances the OEM’s come to us for assistance in blade development.

WPS: And Lakes blades should be expected to perform as good as the OEM versions?

RJ: Our standard for blade life or cycles is to meet or exceed OEM standards. With our proprietary PVD coatings we have exceptional results in blade endurance.

WPS: Do Lakes expand their library of blades as new machines are introduced?

RJ: Lakes Precision is constantly updating our catalogs of blades and accessories. The customer is the driving force in variations of existing blades and new OEM blades being placed in the market.

WPS: From our experience, OEM blade cutting surfaces are typically not covered with any additional coatings which can improve blade life. What blade coatings do Lakes offer to improve blade life even further.

RJ: As mentioned our in house PVD coating department is constantly looking at enhancing blade life. Any blade can be coated and typically titanium nitrite is the standard coating. We take it a step further with blends of various PVD targets and match those coatings to a particular blade application. I believe that we are unique to the industry with coating applications.

WPS: Do you see any trends in the type of blade used in production today. V blades are well known for uniform stripping across a wide range of wire gauges. But are they typically used or do companies opt to use radius style blades for a single wire size that provides stripping around the full circumference of the insulation?

RJ: Our blade development is driven by the wire industry. PVC coated, easy applications, your standard V style blade is by far the most popular. Thinner, smaller, lighter wire require tru-radius style blades. When customers are do high volume runs they prefer the flexibility of the V style blades. Of course we provide any style blade for any size wire.

WPS: Lakes introduced crimp tools as another product offering. Can you describe this program?

RJ: Our crimp tool program is developing each and every day. Our engineering staff work directly with the customer to insure the correct applications. Again we have created PVD coatings that have shown enhanced tooling life while adding minimal coat to the tool.

Thank you for your time today Rich. WireProcess Specialties values our long association with Lakes in providing our customers with high quality replacement tooling for their processing machines.

Click the following links for more information on Lakes Precision, our Global Technology Partners Group , our growing Resources for Wire Processing, or our Services like Crimp Cross Sectioning. We would be happy to Connect with You.

Static vs Dynamic Measurement of Crimp Elements

July 5, 2016 wireprocess Application Illustrations, C&S Technologies, Uncategorized Comments Off

Quality measurement has been an essential part of process validation and control for manufacturing for centuries. Engineering a product design with critical dimensions needs to be validated by quality measurements during the production cycle.

In the early 20th century, statistical analysis of quality was introduced into the quality process of validating manufactured goods and adopted in a number of industries. Automobile production embraced statistical analysis as a result of W Edwards Deming’s influence as the founding president of the American Society for Quality Control.

Today in many industries, a mix of static (one time) and dynamic measurements are used to validate process measurement. In the Wire Process Industry there are a number of measurement tools used which include pull testers, crimp height micrometers and dynamic validation tools such as crimp force monitors. In Wire Processing, dynamic measurement tools are being adopted, aided by the inclusion of them in new processing equipment. But in some respects, a general awareness of the critical nature of dynamic always on quality measurement tools is lacking.

For example, crimp height measurement. Some companies still use the crimp height as a static first off quality measurement and then not measure another part through the balance of the production run.

Or Press Calibration. Calibrating a crimp press with a shut height gauge to the proper shut height without measuring shut height or press force repeat-ability.

These are mistakes. A single part only assures you that that part (or process) is within production tolerances. And does not take into account variation from all input elements in a crimp process.

Dynamic measurement tools provide a piece by piece indication of process capability and detection of crimp errors. Dynamic capability studies of press shut height and crimp force provide valuable information on a press’ ability to supply repeatable crimp force.

Press Analyzer

Here is a clip from our seminar at the 2016 Electrical Wire Processing Technology Expo. This clip illustrates the value of dynamic press analysis.

Static measurements such as crimp height and pull test are not obsolete in today’s production environment. In fact they are valuable first off process validation tools but need to be supported by dynamic measurement from crimp force monitors and crimp camera systems.

MX Series Crimp Force Monitor

So what are the implications of not dynamically measuring crimp elements in real time?

Rework cost from defective product
Related costs and penalties from customers
Lower customer confidence
Maintenance and Quality resources not deployed on priority issues because objective information is not available.

Flip these around and you can see the benefit to your organization. So you say these problems have not occurred to our company? Perhaps not in the past but there is always a real risk of these problems coming up in the future. And without objective analysis, you just don’t know.

Act now. Let us provide you with the tools and services you need to get a start on measuring and improving your crimp quality. Connect Your Way to WireProcess.

You Asked: Frequency of Cross Section Analysis

June 24, 2016 wireprocess Application Illustrations Comments Off

A customer asked this question during a crimp training session I was performing: What Frequency should you perform Cross Section Analysis on a specific wire and terminal combination?

I will provide a response to this question shortly. But you need to understand the uses of Cross Section Analysis. And how it applies go the crimping process in general and specifically how it applies to your company.

For those who are new to this technology, a crimp cross section is an image of the inside of a terminated wire. This image shows the result of how the five elements of the terminal crimp process come together. Valuable information can be pulled from this image. For a more detailed explanation, please read our post Terminal Cross Sectioning: Taking a Peek Inside.

I consider Cross Section Analysis as the Swiss Army Knife of Crimp Quality. A Cross Section can serve many purposes. First as a base line master image of your crimp process in the initial production phase. This is a report that can be retained for future analysis or provided to a customer for their quality audit purposes.

Second, knowing the basic crimp configuration will provide an indication of how the crimp will perform. If the wire and terminal combination are specified and the crimp height is established by the terminal supplier then what you see in the cross section image is generally how the crimp will look through the crimp process. If the crimp wings are touching (or close to touching) the internal crimp walls or floor, this can cause crimp monitor alarms. Or if crimp wings are forming but not capturing stranding (uneven distribution), this is a sign the crimp could perform poorly in electrical testing or in use in the device it is installed into.

Crimp Wings Touching the floor of the crimp.

Under Compressed Crimp

Next, in process validation. Comparing the current image to the master image previously captured. Checking to see if crimp tool wear or other inconsistencies have caused the crimp profile to change.

Finally as a process improvement tool. When crimp elements come together, the process capability is the sum of these elements. Improving any of the elements (press, applicator, wire, terminal, operator/automation system) can improve the overall process. And that results in a better terminated wire.

So coming back to the frequency of cross section analysis, an initial image is important as a base line review of the crimp profile. Where there are crimp problems (crimp monitor “false alarms, customer complaints etc..) a crimp cross section helps to determine in process issues. This would be done on an as needed basis. In process image capture to compare the current image with the master image would depend on the overall volume of that crimp. Also consider any changes in the elements of the crimp process. For example crimp tool changes or wear or an introduction of a new wire supplier. Even as simple as an applicator removal and re installation at a later date can be a factor in variation.

There are no established guidelines on the frequency of cross section analysis other than what a customer may establish. But the use of cross section analysis as a validation, in process inspection and process improvement tool will only increase in the future. And why not? The information from this analysis can lead to a better quality electrical connection and a lower risk of failed electrical circuits from faulty electrical connections.

Global Technology Partners of WireProcess are industry experts in their areas of support to the wire processing industry. C&S Technologies are globally recognized for their expertise in crimp quality. For more information, visit our C&S site and our Crimp Quality Solutions. Connect Your Way to WPS.

Terminal Cross Sectioning: Taking a Peak Inside

April 16, 2016 wireprocess Application Illustrations, C&S Technologies Comments Off

Terminal Cross Sectioning is a quality validation technique that is not new to Wire Processing. The use of cross sectioning has broadened over the past few years and cross section systems are now appearing outside of the quality lab and on the factory floor. This trend is expected to continue in the coming years. Cross section labs are expected to be as commonplace as a pull tester in most processing facilities.

In the past, quality tests of a terminal crimp were performed by only a pull tester and being a destructive test, it was a first off and spot in process inspection. But it certainly did not take into account the inherent process variation of the crimp process itself. Later on as electrical performance demands increased, it was necessary to improve the quality inspection processes. At the same time, crimp design advanced and no longer was just pull test sufficient. Enter crimp compression. Crimp compression standards were a result of studies into crimping and it was determined that a predictable percentage of crimp compression was needed to assure optimal electrical performance. Crimp Height is based on optimum compression of the wire during the crimp process.

With Cross Section analysis, we can now peak inside the crimp. This cross section analysis provides us with a great amount of detail into not only the materials (wire and terminals), but how they are crimped together. Information that is used for documentation and archival purposes. An important aspect of cross section analysis is process improvement. Some of the measurements available from cross sectioning a crimp include:

Crimp Height
Crimp Width
Crimp Compression
Crimp Height to Crimp Width ratio
Capability Studies including crimp height.

Process Improvement is a necessary component of any company who wishes to reduce their processing costs (material waste and processing time) as well as improving overall productivity. Cross Section analysis can be a valuable tool in process improvement. For example, crimp monitor alarms. Crimp monitors signal an alarm when an element of crimp quality causes excess variation. Often the suspect parts appear normal and acceptable. Production continues. Later on another alarm occurs. Same condition. Parameters are opened up and production continues without alarms. But the underlying problem still exists. Once this cycle starts, the monitoring system becomes less sensitive and at some point only gross errors can be detected. And the risk of accepting defective parts also increases.

Cross Sectioning a crimp offers one way of detecting an issue that could be quickly assessed and a resolution put in place. See the illustrations below.

Crimp wings touching crimp floor.

Uncompressed strands and uneven strand distribution.

These are two examples of conditions which can cause variation which a crimp monitor interprets as a defect. Which can affect electrical performance.

Embracing Cross Section Analysis as a critical validation tool is important for companies in the future. Costs have come down to the point where most companies can justify a base system for plant deployment. The WPS Cross Section Service is another way to get your analysis completed while working out the deployment of system for internal use.

Connect Your Way to WPS.

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