Archive for September 2018

Objective Evidence Part Two: Do you really know?

Assumptions may be a tool used in financial forecasting in absence of actual facts but is hardly a good practice to apply to actions around product quality.

This is the conclusion of our series on Objective Evidence as it applies to the terminal crimp process.

Objective Evidence is an important concept to ensure actions from decisions are causing positive results. To review from part one:

Objective Evidence defined: “Information based on facts that can be proved through analysis, observation and other such means of research.” Source:

In this article we explore the production and process monitoring of the terminal crimp process. Ensuring the pre-production validation process continues into production and controls that are in place, effectively reduce the chances of non-conforming assemblies leaving the production facility.

Assuming everything is working simply because you implemented a new monitoring process can lead to unacceptable outcomes. From material rework locally and goods returned from a customer to product recalls. Non conforming (or poorly performing) materials that are introduced into the supply stream can be costly, in monetary and non-monetary ways.

The CFM cycle (click to view video) is an example of an incorrect assumption that simply introducing a crimp monitor on it’s own does not guarantee non-conforming crimps. The reality is Crimp Monitors Do No Solve Your Crimping Problems.

Here are a few important areas to check:

Are your Crimp Monitors detecting crimp defects?

The ability to effectively monitor crimping using a Crimp Monitor (CFM) is affected by a number of factors. The terminal/wire match is one factor, considering Headroom which can influence the sensitivity of crimp monitoring. Equipment condition is another.

  • Duplicate an crimp error like strands missing. Determine if the threshold of the crimp defect detection is acceptable based on your requirements.

Strand Missing from Crimp

Crimp Monitors provide real time monitoring of the crimp process and as stated above the sensitivity of the monitoring process is affected by each element of the crimp process. The wrong tolerance setting whether set too high intentionally or by mistake increases the risk of introducing non-conforming crimps into your product.

Visual and Physical Measurements.

Take a batch of processed wires and fan them out. Check wire position in the crimp to ensure insulation is not in the wire crimp, the bell mouth and brush positions are correct. Measure wire crimp height and pull test and confirm they meet the manufacturer’s specs.

Crimp Height and Pull Test

Operator Bias: Removing Subjectivity from the Crimp Process.

Let’s face it. After a long period of time, operators and set up people can form their own bias towards quality. Left unchecked, this bias can be a problem in improving process quality. And be a process variation itself.

Lock down the validation and monitoring process. Connect your bench and automated crimp machines into a network. Process parameters do not change over time and should be stored in a central database. Create a process where validation of process parameters is required before machines are released for production. Then monitor the process to ensure ongoing conformity to the validated process parameters.

C&S MPN-100 Network

The stakes are never higher than they are today. Exposure to liability from non-conforming products can be reduced by following a repeatable process.

Crimp Quality Solutions is end to end support for the terminal crimp process. Connect with WPS to get started.