Original Date: 05/17/1993
Revision Date: 01/18/2007

The Crane Division-Naval Surface Warfare Center provides manufacturing services including electronic cable and wiring harness interconnect assemblies manufacture. Personnel in this assembly organization actively apply continuous improvement to the manufacturing processes to provide value-added service to the customer. The result of this dedication to improvement and the service to the customer is reduced maintenance cost, increased repairability, and improved responsiveness.

All manufacturing technicians are certified for soldering processes to the requirements of MIL-STD-2000 Category G, and several employees have been certified for crimping, wire wrapping, and inspection criteria. No external quality control personnel are required, and technicians are cross-trained to use all work area equipment and processes. Fully trained technicians interpret technical drawings, schematics, wiring lists, and work instructions. This capability has fostered an environment where design improvements are submitted by the employees to the customer. Such design improvement suggestions have included the use of clamshell connector backshells in place of single piece potted designs, which were not repairable. Crimping wire connections has been suggested to customers over soldering to ensure enhanced uniformity, reduced costs, and elimination of solder wicking. The technicians examine the choice of jacket and tubing materials to ensure low smoke generation, flexibility, chemical/ozone resistance, and durability with each application. The technicians have even addressed environmental issues by recommending the elimination of cadmium-plated connectors that pose problems in manufacturing.

Securing high caliber, team oriented personnel in an environment of reductions and hiring freezes has also been innovatively pursued. For example, cooperative education programs have been used to benefit both participants and the company. Another unique approach is training and employment of non-traditional background personnel on a trial and one-day per week basis.

These practices have provided the Crane Division-Naval Surface Warfare Center's cable and harness assembly customers with improved services, yielding high quality and cost efficient products. The employees have benefited by being recognized as experts and are dedicated to meeting delivery dates at a reduced cost with an improved product. Product improvements have included more durable assemblies, waterproof assemblies, enhanced electrical characteristics, and repairability. The program's success can be directly attributable to employee recognition and involvement by management.

For more information see the Point of Contact for this survey.