Quality management
The reliability of electrical connections determines the functional safety of the entire system. That is why every cable assembly passes through defined quality and testing processes, documented and traceable, from the individual wire to the finished wiring harness.
Electrical testing
Since 2011 our quality assurance system has tested pin assignment, resistance and wiring faults automatically and logged the results. Depending on the requirement, short circuit and high voltage testing as well as functional and load tests are added.
Per wire: assignment · resistance · wiring faults
Test passed · 10/10 OK
Test chain
Documented manufacturing processes and consistent quality assurance detect faults early, reduce scrap and secure a consistently high product quality.
Incoming goods inspection of the components, before wires, contacts and connectors go into production.
Documented processes with crimp force monitoring, dimensional checks, seal position monitoring and cut monitoring.
Continuity and short circuit testing, and depending on the requirement high voltage testing as well as functional and load tests.
Visual and mechanical checks as well as a final inspection of the finished products.
Traceable manufacturing, on request with test logs, measurement reports and customer specific documentation.
Monitoring in the machine
Our fully automatic cable processing machines monitor every step. Faults are detected before a contact reaches the wiring harness.
Crimping
The fully automatic cable processing machines record the force curve of every crimp and compare it with a reference. If the curve deviates (for example because strands are missing or insulation sits in the crimp area), the contact is identified as faulty and ejected.
Sealing
Checks whether the single wire seal sits at the right position on the wire: the precondition for a tight seal inside the connector housing.
Stripping
Detects when the stripping blades touch the conductor as they cut in. That keeps the strands undamaged: the basis for a reliable crimp.
Traceability
Since 2019 an intelligent storage system and a quality assurance system to automotive standards have worked together. Since 2021/2022 an MES has planned every production order by priority, date and customer requirement.
Wires and contacts with a batch reference from the automated store.
Production orders and process data run through the MES.
Electrical testing and final inspection are logged.
Every product is documented without gaps, right up to delivery.
Milestones
The first Komax fully automatic machines as well as further crimping and semi automatic machines: crimped connections and single wire seals have been processed by machine ever since.
Production lines for soldered connections, ESD standards and a system that tests assignment, resistance and wiring faults automatically and logs the results.
Intelligent storage system and a quality assurance system with full batch and process traceability.
Ultrasonic splicing systems and fully automatic cable processing machines with crimp force monitoring (CFA+), seal position monitoring and cut monitoring. The MES followed in 2021/2022.
Our own CAD design office with EPLAN: development of complete cable systems including documentation to PPAP.
Schleuniger B340 with a rotating four blade system: a concentric cut without damaging the conductor.
Key figures
Every first sample is inspected, every wiring harness is electrically tested. We continuously evaluate delivery dates and complaints, since 2019 with full batch and process traceability.
On time delivery
Every production order runs through our MES and is planned by deadline and priority. We see deviations early and report them before the deadline is at risk.
Complaints
They arise almost entirely in first projects in which a requirement had not been finally agreed. After first sample approval, the rate in ongoing series production is considerably lower.
Quote
This applies if the components are stock items or already available. For complex wiring harnesses and special parts we need longer and tell you so.
We give you our current figures for on time delivery and complaint rate in a supplier meeting or in your questionnaire. Write to us using the contact form and we will compile the information for your supplier assessment.
Standards
The basis is a quality management system to ISO 9001. Industry specific requirements (for example from automotive projects) are agreed project by project and implemented in documented form.
Quality management
Quality management to ISO 9001: defined procedures, documented tests and traceable manufacturing. Certified by DEKRA Certification GmbH, valid until 12/05/2028.
Automotive projects
We agree the scope of documentation, testing and approval for automotive customers project by project, on the basis of the customer specifications.
Component protection
We have worked to ESD standards since 2011. Sensitive electronic assemblies are processed in our ESD protected room.
Approval
For series parts we prepare the approval documentation to PPAP in the scope agreed with the customer.
FAQ
More answers about cable assembly can be found in the knowledge section.
Through standardised manufacturing processes, qualified staff and comprehensive testing and inspection procedures. All steps are documented during production and carried out to defined quality standards. The most important measures are:
On request we also prepare test logs, measurement reports and customer specific documentation.
Yes. For series parts we prepare the approval documentation to PPAP (Production Part Approval Process) in the scope agreed with you, typically in automotive projects. Since 2023 our own designs including their documentation have been created in our CAD design office as well.
Yes. Since 2019 full batch and process traceability has been in place: every product can be documented without gaps, from the individual wire to the finished wiring harness.
In a structured way with an 8D report, based on the requirements of IATF 16949: we contain the fault, take immediate action, determine the cause and eliminate it permanently with effective measures. Thanks to batch and process traceability we can quickly narrow down which deliveries are affected.
Yes, gladly by arrangement. Arrange an appointment on +49 9321 3924811 or by e-mail to info@powertune.de. The ISO 9001 certificate is available under Downloads, in German and in English.
Test requirements
Tell us the scope of testing, your documentation needs and the relevant standards. We will match the testing to your project.