This preparatory seminar forms the foundation for our training and continuing education programs and can be booked as an optional add-on to the main seminar.

We recommend the preparatory seminar—which covers the fundamentals of cable processing technologies—not only for newcomers to the field. The topics in this preparatory seminar cover the theoretical fundamentals of cable processing. In addition to the individual manufacturing processes, the focus is primarily on the associated quality requirements. You will gain a thorough insight into the world of cable assembly and crimping technology. You will acquire background knowledge about this technology and learn about the tasks and challenges that cable assembly operations face on a daily basis.

• Seminar Type: Online Seminar
• Dates: By arrangement or according to the training schedule
• Seminar ID: AW-01
• Seminar duration: Approx. 6 hours (2 parts)

Theory & Practice at the Crimp Academy: In addition to the theoretical and technical fundamentals of cable processing, this seminar focuses primarily on the practicalapplication of manufacturing techniques and testing methods in cable assembly.

• Seminar ID: AW-03
• Venue: Crimp Academy, Flandersbacher Weg 6, DE-42549 Velbert
• Seminar duration: 2 days
• Date and Time: By arrangement
• Number of participants: Max. 5 participants
• Target audience: Quality assurance, production planning, machine setters/adjusters, production planning, development

With this comprehensive training program, employees qualify to independently conduct theoretical and practical training sessions within your cable assembly department.

• Seminar-ID: AW-08
• Location: Crimp-Akademie, Flandersbacher Weg 6, DE-42549 Velbert
• Seminar duration: 3 Days

• Date and time frame: By arrangement

The content and requirements of well-known standards and supplier specifications are integral parts of this training (DIN EN, railway standards, IPC, various factory standards from different industries)

Establishing crimping quality standards – Your own factory standard – Supplier specifications.

• Seminar ID: OSS05
• Seminar Type: Online Seminar (Exclusive)
• Seminar duration: 3 seminar sessions (approx. 3 hours each) + 2 individual workshops (approx. 2 hours each)
• Date: By arrangement or according to training schedule
• Target audience: QA, AV

Important: A solid foundation of prior knowledge regarding cable processing and crimping technology is an essential prerequisite for successful participation in this seminar. If this knowledge is lacking or only partially present, the in-person seminar (AW03) on QA/QM in cable processing should be attended first!

What quality standards should be followed in cable assembly? This question is the focus of this seminar, as official standards are generally insufficient.

Depending on the industry, different requirements for crimp quality are set in crimping technology. In this context, official standards (DIN EN, etc.) usually play a secondary role. Industries such as the automotive sector have been working according to their own plant standards and supplier specifications for years. The main reason: Official standards allow too much room for interpretation when evaluating the quality of a crimp connection, or provide no specifications for certain aspects of the crimp connection. This means that a crimp connection that complies with official standards does not automatically meet the requirements in actual use!

When it comes to ensuring crimp quality, the number of units to be manufactured is of crucial importance.

The classifications: In high-volume production, the crimp contacts are precisely matched to the nominal cross-section of the wire. Even if this means that a new crimp contact must be designed and manufactured. For small quantities, existing systems (crimp contacts, connector housings) are usually used. This is more cost-effective, but has the disadvantage that if the nominal cross-section of the wire changes, the crimp connection will have suboptimal crimp quality.

The manufacturing process: In high-volume production, the use of quick-change tools specifically tailored to the crimp contact and the nominal cross-section of the wire is standard. Crimp connections are produced on fully automatic crimping machines equipped with comprehensive monitoring systems. Crimp connections for smaller production runs are manufactured using semi-automatic machines and, very often, hand tools.

One thing is certain: Only a well-executed crimp connection can meet the requirements in use and function reliably over the long term.

Whether you manufacture your crimp connections yourself or source them from an external cable assembly provider: Only if you explicitly define specifications for the execution of the crimp connection can you expect a high-quality crimp connection to be produced that meets the requirements.

Seminar topics:

Part 1 – Fundamentals of Crimping Technology

• Introduction to crimping technology.
• Job profiles in cable assembly.
• Overview of possible quality requirements
• Handling, cutting, and stripping cables and wires.
• Basic requirements for crimp connections:
  - Open crimp sleeves
  - Wire end ferrule
  - Twisted contacts
  - Pre-insulated contacts
• Processing technology:
  - Quick-change tools (semi-automatic and fully automatic)
  - Hand tools
• Crimp quality control – Overview of methods.
  - Visual inspection
  - Pull-out test
  - Measurement of crimp dimensions
  - Cross-section preparation and evaluation
  - Contact resistance measurement
  - Reverse polarity test, latching test, alternative test methods
  - Automatic monitoring methods (e.g., crimp force monitoring)
• Assembly and disassembly of crimp connections.

Part 2 – Quality Management in Crimping Technology

• What do existing standards define?
• FMEA (Failure Mode and Effects Analysis) in crimping technology:
  - What potential sources of error can lead to suboptimal crimp quality?
  - What effects can suboptimal crimp quality have during use?
  - How can defects be prevented?
• Special approvals
• Tools for manufacturing:
  - Specifications
  - Work instructions
  - Test instructions
  - Measurement reports
  - Maintenance schedules
• About Audits of Cable Assemblies

Part 3 - Preparation - Data collection regarding crimp connections.

• Tool list: Which crimp contact is processed with which tool.
• Determine the current crimp quality.
• Update or create new specifications.
• Update or create new data sheets.
• Optimizing Crimp Quality – The Options.
• Define the necessary minimum requirements for crimp connections.

Part 4 - Creating Your Own Factory Standard – Defining Quality

• What should be regulated in the in-house standard / supplier specifications.
• Forms and templates.
• Approvals:
  - Machines
  - Tools for semi-automatic and fully automatic machines
  - Hand tools
  - Work processes
• Required inspections
• Implementation of the factory standard in internal and external manufacturing.
• Training - Dialogue with production.
• Auditing and inspection of cable assemblies.
• Incorporate additional manufacturing processes in cable assembly into the factory standard / supplier specifications.

Participant Certificates: In accordance with the seminar registration, participants will receive a certificate listing the seminar content. You will receive the certificate via email as a PDF. Five participant certificates are included in the seminar price. For each additional certificate, we charge a flat fee of €8

Seminar refreshments: Hot and cold beverages and light snacks (finger food) are provided during the seminars. A light lunch is organized for each seminar day in consultation with the participants through appropriate catering services.

Questions – Technical Processes – FAQ
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