Electric terminal crimping machines - Is SPC appropriate for this process?

ARC05

Registered
#1
G'day all,
We use electric terminal crimping machines in production, crimping small automotive style terminals/pins to wires, e.g. 20 awg. Typically no more than 100 crimps per day per machine.
Every morning, and each time a terminal reel is changed, each machine is verified and calibrated using pull force testing on sample crimps.
- If the result is PASS and >~15% above minimum spec, no adjustments are made,
- If result is PASS and within 15% the settings will be adjusted, retested and then commissioned for use,
- If the result is FAIL, QA Manager is notified and we would investigate cause as well as impact to items produced.
Test results are maintained in hard copy as records.

Question - is SPC appropriate here, and if so how would it help? I figure not due to the daily verification testing. Each time a machine is recalibrated the results are independent of the previous one.
Open to ideas...
Thanks
 
Elsmar Forum Sponsor

AgnieszkaSz

Involved In Discussions
#2
To make this clear - do you want to assess the press, or the applicator, or the process (specific applicator working with specific press)? I gather that the variable will be the crimp height. From my practice - this was done for specific applicator; we used to perform series of 100 samples after each 40.000 crimps and measure all samples. The results should be within tolerance range for particular terminal type, but you can calculate Ppk as well.
 

ARC05

Registered
#3
Hi @AgnieszkaSz thanks for your reply. Sorry I wasn't clear - I don't actually see any need for further analysis / assessment personally. We have daily pull force verification tests for each crimp machine, so I the risk of non-conforming crimps is very low. As I mentioned we do very low volumes.
Background is a 'finding' from a customer audit which says we should be should be using SPC to "monitor consistency and accuracy". So my question was simply whether anyone here can see benefit in exploring any SPC methods in this situation?
 

bobdoering

Stop X-bar/R Madness!!
Trusted Information Resource
#4
You can only use attribute SPC on that type of data. The only variable data from crimping is crimp height, and that data could identify a dies so worn it needs replaced. Not much else will give you valuable SPC data - especially pull-to-failure.
 

optomist1

A Sea of Statistics
Trusted Information Resource
#5
Using continuous or variable data will provide insight as to the direction the crimping process is headed...possibly tooling issues, set up issues etc...much is dictated by your customers specs and acceptance criteria....below is a link to a supplier of tensile test equipment used to perform pull out tests...another more involved and expensive method is to section and examine crimped wire terminal connections....hope this helps


Force Gauge, Torque Gauge, Spring Tester, Pull Tester, Peel Tester Measurement - Mark-10
 
Thread starter Similar threads Forum Replies Date
Marc Electric Car circa 1898 Coffee Break and Water Cooler Discussions 11
R ISO 10079-1:2014 on electric powered nasal aspirator Other US Medical Device Regulations 0
Sidney Vianna NASA to Develop a Novel Approach for All-Electric Aircraft Using Cryogenic Liquid Hydrogen as Energy Storage World News 2
S Beginner trying to OEM a medical device - Branded Electric Acupuncture Pen EU Medical Device Regulations 3
T Weibull analysis of life time test of 8 electric motors until failure Reliability Analysis - Predictions, Testing and Standards 9
S Example Mock Drill Report for EHS in Electric Power Industry Miscellaneous Environmental Standards and EMS Related Discussions 2
M Textile Control Plan for Electric Blanket Factory Supplier Quality Assurance and other Supplier Issues 2
S Common Electric Fan Motor Problems Reliability Analysis - Predictions, Testing and Standards 3
S IQC (Incoming Quality Control) requirement on Electric Power Adaptor for US and CE Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
S Implementing WECO (Western Electric Company) Rules Questions Statistical Analysis Tools, Techniques and SPC 8
R Scope of TS16949 for motorcycle/electric bike tier1 supplier. IATF 16949 - Automotive Quality Systems Standard 1
E Nonconformity on managing documents for Electric Arc Furnace Manufacturing and Related Processes 4
N High Restrict Safety Parts Table of EV (Electric Vehicle) Parts Suppliers? Various Other Specifications, Standards, and related Requirements 3
Marc Factoid: Thomas Edison didn't invent the electric lightbulb Coffee Break and Water Cooler Discussions 6
C Electric Torque and Angle Torque Wrench questions General Measurement Device and Calibration Topics 3
R Design and Development exclusion? We repair and refurbish electric motors ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 5
I Very large scale solar electric system maintenance inspection AQL - Acceptable Quality Level 5
T Poor Capability - Electric torque screwdriver Capability, Accuracy and Stability - Processes, Machines, etc. 2
L Question: outsource medical device electric safety test to OEM supplier ISO 13485:2016 - Medical Device Quality Management Systems 3
Marc How GM Plans To Dominate The Electric Vehicle Market World News 9
Marc The rebirth of the electric car? GM's Chevy Volt World News 15
C Electric Signs Certification - UL standards exist - Are there any european ones? Various Other Specifications, Standards, and related Requirements 3
M Vibration Measurement - Pump Driven by an Electric Motor Misc. Quality Assurance and Business Systems Related Topics 8
J Western Electric Company (WECO) Rules - How many are there? Statistical Analysis Tools, Techniques and SPC 11
Marc Electric cars as fast as a Ferrari World News 1
S Environmental Management Program - Reducing electric and fuel use, waste management Miscellaneous Environmental Standards and EMS Related Discussions 25
W Reduction of negative impact on the enviroment (electric energy comsumption and unde) Miscellaneous Environmental Standards and EMS Related Discussions 3
B Electric 0-8" Caliper Calibration Tolerance Question. General Measurement Device and Calibration Topics 9
T Turnover good for Quality? Is all employee turnover bad? Not at General Electric Career and Occupation Discussions 7
M Western Electric Statistical Quality Control Handbook Statistical Analysis Tools, Techniques and SPC 3
L Terminal Block use in compliance to IEC 60601-1 IEC 60601 - Medical Electrical Equipment Safety Standards Series 3
T Preventing Wrong Terminal Crimped on a Wire Harness Manufacturing and Related Processes 7
optomist1 Tensile Test Crimped Electrical Terminal Acceptance Criteria Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
H What does the abbreviation for ?POAG? terminal/stud stand for? Manufacturing and Related Processes 3
M IPC-A-610 vs. Our Specification - Not Staking Wire through a Bifurcated Terminal Various Other Specifications, Standards, and related Requirements 4
E Marking the material category for Component Terminal Finish (Jedec J-std-609)? Manufacturing and Related Processes 1
A Radio & Telecommunications Terminal Equipment Directive 1999/5/EC CE Marking (Conformité Européene) / CB Scheme 5
G Control Chart Selection for Crimping Operations for RJ 45 Plugs Statistical Analysis Tools, Techniques and SPC 5
P Relationship between Crimping ID & Crimping Depth - Minitab usage Statistical Analysis Tools, Techniques and SPC 3
D Project to Reduce Destructive Sampling in Crimping Process Inspection, Prints (Drawings), Testing, Sampling and Related Topics 3
A Mil Standard for Crimping Various Other Specifications, Standards, and related Requirements 5
Similar threads









































Top Bottom