Levers in design
- Reduce variants: one wiring harness for several equipment versions saves setup and administrative effort
- Standardised connectors and contacts instead of many special parts
- Optimise cable lengths and branches, without unnecessary reserves
- Size cross sections to what is actually needed, not oversized across the board
- Use protection selectively: corrugated tube where it is needed
- Place separation points so that assembly and servicing become easier
Levers in purchasing
- Realistic annual quantities and stable call-offs make economical lot sizes possible
- Framework orders secure material and capacity
- Define available alternatives for critical components early
- Choose the scope of testing and documentation to match the risk, appropriate rather than maximum
Involve the cable assembly supplier early
The most effective savings come about when design and production work together early on. A cable assembly supplier with its own design office spots production friendly solutions before they become expensive. These might be contacts that can be processed automatically, for example, or a cable routing that is quick to build on the assembly board.
At Powertune, design, samples and series production are under one roof. It is best to talk to us while you are still in the development phase.
Where you should not save
- On the crimp: the right contact, the right tool, a monitored process
- On electrical final testing
- On seals and cavity plugs in damp environments
- On strain relief and protection at chafing points
