Zero-Defect Manufacturing
Developing manufacturing, assembly and test procedures which will insure "zero defect" quality standards and strict adherence to customer/military qualification specifications is the first order of business when building TIFTAC and other mission-critical cable assemblies. The assembly of high performance interconnect cables for use in military and commercial applications is simply not possible in any setting other than a tightly controlled, 100% inspection and test environment. All of ABC's overmolded cable assemblies are manufactured in just such a setting, and meet the most stringent reliability requirements for rough handling and harsh environmental conditions. Overmolded assemblies are typically manufactured using either one-of-a-kind transfer molds or high volume injection molding machines. In the case of the F-16 TIFTAC, a range of new injection molding equipment and tooling was required to meet the production forecasts and quality control requirements of the customer, General Dynamics-Fort Worth.
F-16 TIFTAC cable assemblies are fabricated in accordance with General Dynamic's original specification control documentation and a host of relevant Mil-Spec standards in a tightly controlled "closed-loop" assembly process. In order to qualify to produce the F-16 TIFTAC assembly, and to extend the qualification by similarity to other fuel tank cable assemblies, Glenair's ABC division instigated dedicated TIFTAC manufacturing controls and procedures which segregated the fabrication process from all other operations on the ABC shop floor. From the receipt and storage of incoming materials to the final test and inspection of the finished cables, TIFTAC manufacturing is accomplished with dedicated personnel using tightly controlled tooling and equipment. The manufacturing control procedure developed by ABC for the production of the F-16 TIFTAC includes the following processes and controls: (1) Incoming material inspection and storage: all materials are inspected upon receipt and segregated in a controlled TIFTAC stock room. (2) Bulk cable fabrication: specially trained staff insure 100% inspection and test of color coding, lay length and direction, tape overlap, cable tension, diameter, respooling and storage. (3) TIFTAC cable jacketing: cutting, breakout, hand lay-up, taping and Viton® jacketing is completed in preparation for interconnect component installation and termination. (4) Surface preparation of component parts: Special Glenair proprietary processes insure proper adhesion of molding compounds to plated components. (5) Breakout and bulkhead feed through molding: specialized interconnect components and cable breakouts are abraded, primed and molded in place using special Glenair proprietary processes. (6) Connector termination: trained and certified staff position molding adapters and follow approved assembly instructions to complete crimping, termination and 100% in-process inspection. (7) Connector molding: molding adapters are prepared and installed to connectors using thread sealing compound. Curing, potting and Viton® molding and over-molding is completed according to exact design specifications. (8) Identification: color coding, stamping and identification documentation is completed prior to final inspection. (9) 100% final inspection: appearance, identification, dielectric, continuity, and insulation tests are completed on a 100% basis in preparation for final customer source inspection. Viton® is a registered trademark of DuPont Dow Elastomers. |
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