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/.

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

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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

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What is Risk for Your Custom Cable?

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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

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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

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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

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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

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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

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Managing Risk for Your Custom Cable

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Managing Risk- Quotation
 Is the quote documentation
clear?
 Does the quote match the scope
of work required?
 Tooling, NRE, Engineering Fees
 Tariffs

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Managing Risk- Design Freeze
 Require a drawing
 Include a pinout
 Design for manufacturability
 Document testing
specifications

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Design Options to Reduce Risk

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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

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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

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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

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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

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Case Studies: Charging Cables

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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

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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

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 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

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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

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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

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How To Get Started With Your Custom Build

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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

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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.

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Summary

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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.

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Our Products
Battery Packs Flex & Rigid-Flex PCBs Cable Assemblies Printed Circuit Boards
RF Products User Interfaces Flexible Heaters EC Fans & Motors

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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

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Thank You
Check out our website at www.epectec.com.
For more information email sales@epectec.com.
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