Z
I am going to give a lot of detail so that we can focus on solutions, and not a lot of questions.
I am new to this very small manufacturing company, hired as quality manager to help with ISO9001 compliance. I am certified ISO9000 internal auditor and working towards a six sigma green belt. This company has no real procedures or controls of anything.
My customer asked for a corrective action on what they classify as a severe failure...a ten guage wire with an attached ferrule pulled out of a breaker in an electrical assembly. The ferrule did not pull off the wire, the ferrule pulled out of the breaker.
I have started a six sigma project of this failure and determined that the failure is associated with the torque force applied to the breaker wire clamp.
I was considering creating a procedure requiring the clamping screw to be torqued to manufacturer or drawing requirements.
I also considered measuring the ferrule clamping force to prevent any problems in that area....
However, my customer suggested that we create a technique to measure the pull force of the wire and ferrule in the breaker clamp. He suggested that we create our own guidelines... I don't want to do this because of the time and while I enjoy statistics I am not an expert... Also I want something that will be harder to refute than my experimentation.
Well, I know when I don't know something so I decided to look for a standard. UL-486 is expensive and I cannot get much information on EIA-364-38 which might work. My concern here is that most of these tests seem to be testing the pull force to remove the wire from the ferrule and I am concerned about the connection between the ferrule and the breaker.
I am reading an article and the author recommends against 100% in process pull testing, because of possible damage.
What I need is a suggestion on a standard, or a method, for inprocess electrical inspections of this connection.

zekeQA
I am new to this very small manufacturing company, hired as quality manager to help with ISO9001 compliance. I am certified ISO9000 internal auditor and working towards a six sigma green belt. This company has no real procedures or controls of anything.
My customer asked for a corrective action on what they classify as a severe failure...a ten guage wire with an attached ferrule pulled out of a breaker in an electrical assembly. The ferrule did not pull off the wire, the ferrule pulled out of the breaker.
I have started a six sigma project of this failure and determined that the failure is associated with the torque force applied to the breaker wire clamp.
I was considering creating a procedure requiring the clamping screw to be torqued to manufacturer or drawing requirements.
I also considered measuring the ferrule clamping force to prevent any problems in that area....
However, my customer suggested that we create a technique to measure the pull force of the wire and ferrule in the breaker clamp. He suggested that we create our own guidelines... I don't want to do this because of the time and while I enjoy statistics I am not an expert... Also I want something that will be harder to refute than my experimentation.
Well, I know when I don't know something so I decided to look for a standard. UL-486 is expensive and I cannot get much information on EIA-364-38 which might work. My concern here is that most of these tests seem to be testing the pull force to remove the wire from the ferrule and I am concerned about the connection between the ferrule and the breaker.
I am reading an article and the author recommends against 100% in process pull testing, because of possible damage.
What I need is a suggestion on a standard, or a method, for inprocess electrical inspections of this connection.

zekeQA
