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Improving Cable Assembly Reliability in a High-Vibration Application
Background
Safety and Reliability Risks in a Constrained Design
A global automation OEM building AI-enabled warehouse automation systems encountered field issues with a cable assembly used in high-density, autonomous material-handling environments.
The assembly operated in a tight routing area with sharp bends and constant vibration, causing heat-shrink tubing to become unseated and raising safety, reliability, and uptime concerns.
The customer needed a fast, production-safe fix—along with a lower-cost, more reliable long-term design.
Our Approach
A Two-Phase Strategy Balancing Speed, Safety, and Cost
Phase 1: Bottleneck Analysis
MRG evaluated the production process to isolate the primary constraint:
- Manual strip/crimp operations limiting throughput
- Excess handling increasing variation and cycle time
Phase 2: Automated Execution
MRG transitioned the process to automation to support growth and consistency:
- Deployed automated strip and crimp equipment
- Partnered with equipment suppliers for rapid implementation
- Integrated in-line quality monitoring
Breakthrough Impact
Fast Stabilization and Long-Term Cost Reduction
The combined approach delivered both immediate stabilization and long-term improvement:
40,000+ assemblies
40,000+ cable assemblies installed within
12 months across new production and
field replacements<30 days
<30 days to implement
the initial corrective action
in the field22% cost reduction
22% overall cost reduction achieved by
eliminating manual potting and improving
assembly efficiencyImproved safety
Significantly improved safety and
reliability with enhanced strain relief
and termination protectionAwarded
Awarded additional project
releases in multiple OEM sites
Why MRG Won
Speed, Collaboration, & Design-Driven Execution
MRG balanced speed, collaboration, and design expertise to resolve the issue:
Application-driven engineering for high-vibration, safety-critical environments
Rapid quality resolution without disrupting production
Design-for-manufacturability improvements that reduced cost and improved consistency
Cross-functional collaboration with the customer and MRG
Stable, reliable production performance through the design transition