Quality Specification

Crimped Electrical Connections

REVISION HISTORY
INDEX DESCRIPTION BY APPR DATE
1.0 INITIAL RELEASE GMK JMK 03/18/14
2.0 Capability indices target in section GMK JMK 11/18/14 8914 PLEASANTWOOD AVE.
4.2 were 1.33 NORTH CANTON, OHIO 44720

TNC TVN APPLICATION

AUTHORIZED DISTRIBUTION
This document is a corporate quality specification for application in all crimping
FAA: J. Komer/ N.C. Tan 18NOV14
processes regardless of site location. It is intended for use in its entirety upon final
CHECKED BY: L.T. Tung 18NOV14
DRAWN BY: g. Kessler 18NOV14 approval, and supersedes all other documents of internal origin that imply
RELEASE RESPONSIBILITY DATE contradiction or ambiguity to its contents.
CONTROLLED SPECIFICATION No. REVISION
The contents of this document are considered proprietary.
Its distribution is intended for internal use only. Any copies CQS001 2.0
made in whole or part and in any media must be SIZE DWG. SCALE SHEET No.
authorized and verified against the document master list None of the drawings in this
prior to distribution. A document are to scale. SHEET 1 of 12
 PURPOSE
This specification provides product realization quality criteria for producing a mechanical and electrical connection between a
conductor and a component where the component is designed to be attached to the conductor by means of deforming its crimp
barrel or tab(s) using crimping systems specifically designed for the purpose.
SCOPE
This specification establishes the requirements for the standardized methods of evaluating the quality of crimped-type electrical
connections to solid or stranded (coated and uncoated) conductors. It is applicable to the assessment of crimp quality for verifying,
monitoring and controlling the crimping processes required to construct prototype, pre-launch, rework and production assemblies.

1 APPLICABLE INDUSTRY STANDARDS

IPC/WHMA-A-620 Requirements and Acceptance for Cable and Wire Harness Assemblies
UL310 Electrical Quick Connect Terminals
SAE/USCAR-21 Performance Specification for Cable-to Terminal Electrical Crimps
ASTM B 913-05 Standard Test Method for Evaluation of Crimped Electrical Connections to 16-Gauge and Smaller
Diameter Stranded and Solid Conductors

2 DEFINITIONS
Acceptance Class -the following definitions for Class have been established in industry standard IPC/WHMA-A-620.
Class 1 – General Electronic Products
Class 2 – Dedicated Service Electronic Product
Class 3 – High Performance Electronic Products
Applicator- the platform in a crimping system where the crimp dies are installed to deliver the force required to deform the
component crimp barrel or tab(s).
American Wire Gage (AWG)- A standard system for designating wire diameter. Primarily used in the United States.
Bellmouth- The raised portion at the front and/or back of the wire barrel crimp that provides a gradual entrance and exit for the
wire strands without causing damage.
Circular Mil Area (CMA)- cross-sectional area of the current carrying portion of a conductor expressed in circular mils.
Conductor Brush- the portion of the conductor that extends beyond the conductor crimp barrel on the mating part side.
Cut Off Tab- The small tabs that remain on the front and back of a terminal after it has been applied.
Crimp Compression (Compaction)- the reduction in the cross sectional area of the combination of the crimp barrel and the
conductor caused by crimping the component onto the conductor. (Strands are deformed to polygonal shapes with no air gaps).
Crimp Force- the amount of force required to deform the crimp barrel or tab(s) around the wire.
Crimp Height- the height of a deformed crimp barrel after the component has been crimped onto the conductor.
Crimp Ratio- the relationship between the crimp height and crimp width when measured and expressed as a ratio.
Crimp Tooling Dies-the anvil and punch in a crimping system that deforms the component crimp barrel or tab(s).
Crimp Width- the width of a deformed crimp barrel after the component has been crimped onto the conductor.
Crimping System: the complete system for generating and delivering the force required to deform a crimp barrel.
Environmental Chamber- a test apparatus capable of changing and holding temperature or temperature and humidity at a
controlled rate and defined dwell time.
F-Crimp- crimp profile used to close a U-shaped open barrel to confine and compact the conductor during the crimping cycle.
This profile is also common as an insulation crimp.
Flag Type Terminal- an asymmetrical terminal that incorporates a tab lock to support the asymmetrical forces when in use.
Key Characteristic- a characteristic or feature of a product that potentially decreases the functionality or reliability of the product
if processed outside its specification limits.
Key Process- a process where equipment parameters instead of product characteristics are monitored to determine product quality.
O Crimp- An insulation support crimp for open barrel terminals with a crimped form resembling an O. It conforms to the shape of
round wire insulation.
OEM Component- a product such as a quick connect terminal where the original equipment manufacturer specifies the design and
application requirements of the product, and is responsible for its manufacture and reliability.

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 2 OF 12
 Overlap Crimp- crimp profile used to close a U-shaped open barrel to confine and compact the conductor during the crimping
cycle, but one wing/tab overlaps on top of the other. This profile is also common as an insulation crimp.
Press- the equipment in a crimping system that generates the force required to deform the component crimp barrel or tab(s).
Press Repeatability- the ability of the press to repeat force and shut height from cycle to cycle.
Process Indicator- a condition that neither fully meets the preferred acceptance criteria, nor is considered a defect.
Pull out Force- the applied force needed to dislodge a crimped component from the conductor.
Strip Length- the stripped end of an insulated lead wire intended for connection to other components or for customer hook up
options after delivery of the product. For value added thermal protectors, the strip length designated for connection to the thermal
protector is typically referred to as the –A- strip.

3 CONTROL OF CRIMP CHARACTERISTICS

3.1 CHARACTERISTICS OF A TYPICAL OEM QUICK CONNECT TERMINAL CRIMP

(H)
(D)
(C)
(E) (G)
(A) CCW
(I)
(E)
(B)

*CCH

Compression
(F) (Compaction)
Area (D) Crimp Barrel in Cross Section
(E) Conductor Crimp Seam

ICW

(F) (B)
(C) (H)
(A)
ICH

Strip Length (I)

(G) Insulation Barrel in Cross Section
(A) Conductor Brush; (B) Bell Mouth; (C) Wire Insulation (H) Insulation Crimp Seam
(F) Mating Part of the Terminal (I) Insulation Crimp Side Support

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 3 OF 12
3.2 CHARACTERISTICS OF A TYPICAL VALUE ADDED THERMAL PROTECTOR CRIMP
(E)

(D)

CCW
(E)
(D) (E)
(C) *CCH
(B)

(A) Compression
ead (Compaction)
nL
Ca
Area
(D) Crimp Barrel in Cross Section
(E) Conductor Crimp Seam
Plate Lead
(A) Conductor Brush; (B) Bell Mouth; (C) Wire Insulation

3.3 STANDARDIZED MEASUREMENT AND TEST METHODS

In general, instrumentation used in the measurement and test of key characteristics (KC) as denoted by (*) shall be capable of
measuring with a resolution 10x better than the specified value of the characteristic. The instrumentation shall be calibrated and shall
achieve a repeatable accuracy that contributes to the total variance by no more than 30%.
Unless otherwise specified in this document or on the manufacturing drawing, the standard units of measure shall be expressed as:
Area: circular mils or inch2
Force: pounds
Humidity: %R.H.
Linear distance: decimal inch
Resistance: mΩ
o
Temperature: C
Circular Mil Area (CMA) Measurement- determined mathematically by either:
Strand diameter (d) measurement where nominal CMA = (d x 1000)2 x strand count. For stranded conductors, d is determined by
averaging 25% of the total strand, or;
Weight measurement of a 4ft section of wire multiplied by C factor where CMA = wgt. (in grams) * 182.07687
Conductor Crimp Compression (Compaction) Measurement- determined with cross section analysis equipment by measuring the
conductor area of the crimp in cross section, and expressing the reduction in area as a percent of the specified (or measured)
conductor cross sectional area. (Strands are deformed to polygonal shapes).
*Conductor Crimp Height (CCH) Measurement- measured with an outside crimp micrometer equipped with a specialized anvil
and spindle for measuring crimps. Cross section analysis equipment can also be used as a suitable substitute for a crimp
micrometer.
Conductor Crimp Ratio (CCR) Measurement- determined mathematically by CCH ÷ CCW
Conductor Crimp Width (CCW) Measurement- measured with calipers. Cross section analysis equipment can also be used as a
suitable substitute for a crimp micrometer.
Crimp Force Measurement- measured with an automatic Crimp Force Monitor equipped with sensors mounted either to the press
frame or in the base, depending on the conductor gauge. The CFM compares crimp force signatures to a known (teach-in)
reference and either passes or fails the resulting crimp.
Crimp Resistance Test- measured at room temperature by connecting the crimped lead to a 1.0A /3.0VDC circuit and measuring
the voltage drop between the conductor and the crimp barrel with a multimeter. A micro-ohm meter can also be used as a suitable
substitute.

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 4 OF 12
 Conditioning Test- conducted in an environmental chamber capable of controlling conditions within 1.5% of the specified test
parameters where conditions are monitored with synchronized data loggers at a sampling rate of at least every two seconds.
Insulation Crimp Height (ICH) Measurement- measured with an outside crimp micrometer equipped with a specialized anvil and
spindle for measuring crimps. Cross section analysis equipment can also be used as a suitable substitute for a crimp micrometer.
Insulation Crimp Width (ICW) Measurement- measured with an outside crimp micrometer equipped with a specialized anvil and
spindle for measuring crimps. Cross section analysis equipment can also be used as a suitable substitute for a crimp micrometer.
Press Repeatability Analysis- measured by recording the amount of force (in Newtons) and the relative shut height of a crimping
press when cycled 100 consecutive times. NOTE: presses equipped with CFM sensors in the base should not be subjected to more
than 2.5kN.
Process Capability Indices- determined mathematically for a statistically stable process based on;
USL − LSL USL − X X − LSL
Cp = and Cpk = min [ , ]
6σ R 3σ R 3σ R
*Pull out Force Test- measured by positioning the test sample between a clamp and a load cell and applying an axial force at a
steady rate of 25mm ~ 200mm/minute until the conductor dislodges. Insulation bands are removed prior to conducting the test.
Strip Length Measurement- measured from the cut end of the conductor to the nominal edge of the stripped insulation using
standard calipers.
Temperature Rise Test- measured by attaching a thermal couple to the crimp connection and measuring the ∆temp when an
electrical load is cycled ON/OFF ten times with a cool down OFF period that achieves ambient temperature between each cycle.
*denotes a Key Characteristic (KC) measurement or test.

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 5 OF 12
3.4 KEY CHARACTERISTICS MEASUREMENT AND TEST
3.4.1 Specimen Preparation
Lead wires shall be prepared and inspected according to The same procedure shall be followed for insulated crimp
Thermtrol Corporate Quality Specification CQS002. barrels except accurate CCH measurements require substituting
the insulated crimp barrel with a slug of solder wire.
Components shall be identified, and their identification shall be
included in all records resulting from measurement and test The wire diameter of the solder slug is dependent on the wire
activities. gauge to be crimped and the terminal type based on the table
below.
The crimping system shall be identified and the status known
for: Wire Gauge
Solder
Solder Wire
a) the number of hits for crimp tooling dies with wear status Terminal Type Wire Dia.
Range (in AWG) Composition
(in inches)
evaluated at a maximum count of 500K, then re- 26 – 18 Straight 0.125
evaluated every 250K. 60Sn40Pb
22 – 18 Flag Style 0.187
Solid Core
16 – 14 Both Straight & Flag 0.187
b) the number of cycles and preventive maintenance status
for the applicator or hand tool.
Pull out force tests shall be performed on 20% of the specimens
c) the number of cycles for the press with repeatability selected for measurement and test.
status analyzed at every 750K cycles.
Pull out force tests shall be performed by qualified personnel,
The target conductor crimp height dimension and tolerance and shall follow the procedure below for pull testers:
limits shall be stated prior to equipment set up.
a) Verify the pull tester’s calibration status.
Conductor crimp height and tolerances shall be established
b) Remove the insulation crimp, if applicable.
based on evaluation of crimp geometry and compaction as a
portion of APQP. c) Load the terminated lead into the pull tester, and verify
the load cell zero setting is <0.5lbs.
Specimens shall be representative of the intended crimping
system, and shall be randomly selected in subgroup quantities d) Apply the force at a steady rate until the conductor
that best represent the crimping process population. dislodges from the crimp barrel.

3.4.2 Standardized Measurement and Test Techniques

CCH measurements shall be performed on 100% of the
specimens selected for measurement and test.
CCH measurements shall be performed by qualified personnel, The lead wire should be pulled

Force applied axially to the terminal connection

and shall follow the procedure below for crimp micrometers: taut when loading it into the
pull tester to avoid jerking.
a) Verify the micrometer’s calibration status.
b) Zero the micrometer in the closed position prior to
measuring the first specimen.
c) Open the micrometer and position the crimp seam
against the anvil.
d) Make the CCH measurement at the center of the crimp
barrel as referenced by the center lines labeled AA or Remove insulation crimp
BB in sections 3.1 and 3.2 of this specification. prior to loading the lead
into the pull tester.

*Pull out Force Test

For conformance to industry standards SAE/USCAR-21 and
IPC/WHMA-A-620 Class 2 and Class 3, a controlled rate of
25mm to 50mm/minute is required and a manual pull tester
(shown) may not be suitable.
*CCH measurement with a crimp micrometer

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 6 OF 12
3.4.3 Measurement and Test Acceptance Criteria
Specimen acceptance for CCH measurements shall be based on the crimp height dimension specification. Any specimen that measures
outside the tolerance limits of CCHSPEC is unacceptable.
Specimen acceptance for pull out force tests shall be based on the relationship to the conductor size as shown on table below. Any
specimen that tests below the minimum force for its conductor size is unacceptable. If multiple wires are to be crimped in the same
terminal, tensile pull testing is to be performed on the smallest wire in the group.
Conductor Size Minimum Pull Out Force
AWG (mm)2 Pounds (N)
28 0.080 2 8.9
26 0.130 3 13.4
24 0.200 5 22.3
22 0.324 8 35.6
20 0.519 13 57.9
18 0.823 20 89.0
16 1.310 30 133.5
14 2.080 50 222.5
12 3.310 70 311.5
10 5.261 80 356.0
8 8.367 90 400.5
Minimum Pull out Force by Wire Size
3.4.4 Visual Acceptance Criteria
Specimens shall also be 100% inspected under 20x or greater magnification for the following process indictors:
1) The conductor brush is visible.
2) The presence of the rear bell mouth.
3) No visible strands outside the conductor crimp barrel.
4) No obvious damage to the conductor crimp, insulation crimp, component insulation or mating part of the
terminal.
ƒ For automotive supply chain applications, reference shall be made to industry standard SAE/USCAR-21when further
clarification is needed in judging visual acceptance.
ƒ For all others, reference shall be made to industry standard IPC/WHMA-A-620 when further clarification is needed in
judging visual acceptance.
3.5 AUTOMATIC GAGING REQUIREMENTS
3.5.1 Positive Stops
All crimping systems shall be equipped with a positive stop or For semi-automatic presses, the CFM shall include a lock-out
equivalent means to prevent over insertion of the conductor in feature that prohibits the operator from actuating the press until
the conductor crimp barrel. the teach-in parameters have been set.
For thermal protectors, the positive stop shall maintain a For automatic presses, the CFM shall actuate a sub-routine that
minimum specified distance between the plate lead conductor cuts off and sorts rejected crimps to a containment bin.
and the thermal protector can per CQS003.
The CFM teach-in feature shall only be accessible by qualified
3.5.2 Crimp Force Measurements personnel, and shall follow the set up procedure below:
Auto feed presses that produce one crimp per each stroke of the a)Produce measurement and test specimens with the
ram shall be equipped with automatic CFM gaging capable of CFM activated.
measuring crimp force signatures for 8AWG to 28AWG wire b) Verify the specimens meet the criteria in sections 3.4.3
sizes.
and 3.4.4 of this specification.
For semi-automatic presses, CFM sensor sensitivity and c) Verify the CFM parameters are set to detect and reject;
mounting locations shall be determined by wire gauge: ∗ a low insertion lead wire.
Sensor Press Location Wire Gauge Range ∗ a lead wire with a Class 1 maximum severed
0 – 5 VDC signal (piezo) Base plate < 20AWG strand count as defined in CQS002.
50mV/μ strain Press frame >20AWG d) Produce known reject samples.
e) Verify the CFM detects and rejects the known reject
The CFM shall have a programmable teach-in feature, and shall samples.
automatically reject crimps that fail the teach-in parameters. f) Reset the CFM.
The CFM reset shall only be accessible by qualified personnel.

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 7 OF 12
4 VERIFICATION OF THE CRIMPING SYSTEM
The requirements defined in sections 3.4 and 3.5 of this specification shall be met prior to conducting verification measurements and
tests of the crimping system.
4.1 CROSS SECTIONAL ANALYSIS OF THE CRIMP BARRELS
4.1.1 Minimum Equipment Requirements 4.1.3 Quantitative Variables in Cross Section Analyses
- 320k pixels CCD camera optics with 45x to 260x CCW
Crimp
zoom lens Seam
- Image capture and analysis software capable of Cracks not permitted
measuring crimp height, crimp width, and radii to *CCH

within 2μm, measuring angles to within 0.05o, Lowest

Burr Hgt.

calculating crimp compression to within 0.05% and -A- position of

the crimp
Burr Width
strand counts SECTION AA
- Holding fixture
- Speed controlled turntable with adjustable –Z- axis CCW
Crimp
fixture holder Seam

- Micro-grain polishing disc Cracks not permitted

- Jeweler’s saw *CCH
- Copper etching solution
Lowest Burr Hgt.
-B- position of
the crimp
4.1.2 Cross Sectional Analysis Procedure Burr Width
Cross sectional analysis shall be performed by qualified SECTION BB

personnel, and shall follow the procedure below:

Max. Burr Hgt.

(Compaction)
Strand Count

Compression
Crimp Seam
a) Verify the equipment’s calibration status.

Max. Burr
Reduction
Chara./

*CCH

Width
CCW

Gap
b) Verify the wire conductor CMA. Industry

c) Clamp the specimen squarely in the holding fixture.

Automotive Per Per <
Not
d) Cut the conductor crimp barrel transversely at its center supply -0- terminal
spec.
terminal
spec.
allowed
datum
–A-
0.1mm (All strands)
chain
as referenced by the center lines labeled AA or BB in Per Per < one 0.5x
Non- Per 10% ~ 30%
sections 3.1 and 3.2 of this specification. Note: for automotive CQS002
terminal
spec.
terminal
spec.
strand
dia.
material
thickness
N/A
(all strands)
serrated crimp barrels the crimp should be cut at a Thermal Per Per Per
< one < .008”
10% ~ 35%
strand datum N/A
location other than a serration point. Protectors1 CQS002 CQS003 CQS003
dia. –B-
(all strands)
1
Thermal protectors intended for the automotive supply chain must conform to
e) Polish and etch until the individual conductor strands automotive supply chain requirements.
are discernable.
Crimp
f) Confirm camera lens, zoom factor and unit of measure Seam ICW ICW
in the software.
g) Count the conductor strands.
ICH ICH
h) Measure CCH, CCW, and gap at the crimp seam.
i) Measure flash (burr) height and width.
Side Side Side
j) Measure for conductor crimp compression Support Support Support
Insulation Crimps in Cross Section
(compaction).
k) Examine the deformed crimp barrel for cracks or other
Strand Count

Side Support
Crimp Seam
Reduction

Cracks

damage. Chara./
ICW
ICH

Gap

Industry
To analyze the insulation crimp, repeat steps a) through c) and
cut through the mid-point of the insulation crimp barrel. Automotive
supply Per Per
Repeat steps e) through h) replacing CCH and CCW with ICH chain -0- terminal terminal < 45o > 180o
Not
permitted
and ICW. Measure side support. Non- spec. spec.
automotive
Repeat step k). Thermal
Does not apply
Protectors

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 8 OF 12
4.1.4 Qualitative Variables in Cross Section Analyses
Conductor strands captured in the conductor crimp barrel shall be 100% deformed into polygonal shapes with no visible air gaps.
Industry standard SAE/USCAR-21 shall apply for judging qualitative variables in conductor crimp and insulation crimp attributes that
must comply to automotive supply chain applications.
For non-automotive supply chain applications, industry standard IPC/WHMA-A-620 shall apply for judging qualitative variables in
conductor crimp and insulation crimp attributes.

When performing cross section analysis on terminals equipped with cable seals, the following qualitative criteria shall apply:
TERMINAL TERMINAL TERMINAL
SEAL SEAL SEAL

WIRE INSULATION WIRE INSULATION WIRE INSULATION

CONDUCTOR STRANDS CONDUCTOR STRANDS CONDUCTOR STRANDS

Sealed insulation crimp attributes considered ideal

PINCHED SEAL IN THE INSULATION GRIP OVERCRIMPING -DEFORMATION OF THE TERMINAL & SEAL
(no damage) (no damage)
TERMINAL TERMINAL TERMINAL TERMINAL
SEAL SEAL SEAL SEAL

WIRE INSULATION WIRE INSULATION WIRE INSULATION WIRE INSULATION

CONDUCTOR STRANDS CONDUCTOR STRANDS CONDUCTOR STRANDS CONDUCTOR STRANDS

Sealed insulation crimp attributes considered undesirable but acceptable

CRIMP WINGS PENETRATE SEAL or NICKS & CUTS IN THE SEALING NECK OR RIBS
TERMINAL TERMINAL
SEAL SEAL

WIRE INSULATION WIRE INSULATION

CONDUCTOR STRANDS CONDUCTOR STRANDS

Sealed insulation crimp attributes considered undesirable but acceptable

4.2 CRIMPING PROCESS CAPABILITY

The crimping process shall be considered capable when pull out force and CCH are statistically stable, and the total process variation
of CCH is < 50% of the total specification limits for CCH. Thus, when sigma is estimated by

R
σ̂ =
d2
where d2 is the range control chart factor for centerline, CCH shall achieve Cp > Cpk > 2.00.
Short term capabilities studies shall be performed requiring the analysis of CCH data from a minimum of 6 subgroups of 5 specimens
each with 20% from each subgroup subjected to pull out force tests.

4.3 REPORTING VERIFICATION OF THE CRIMPING SYSTEM

The results of sections 4.1 and 4.2 shall be documented in the Terminal Verification Report (TVR).
The TVR shall be made available as a portion of design validation prior to Design Freeze, and maintained as a quality record.
The TVR shall be made available for customer approval when any part of the crimping system differs from or is ambiguous to
customer expectation ns.
The TVR shall be made available as a portion of PPAP documentation when such documentation is required by the customer’s
production part approval process.

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 9 OF 12
4.4 CRIMPING PROCESS CONTROL
4.4.1 General
The natural tendency to focus process control parameters around data collection that is part number specific should be avoided when
monitoring crimping process control. Such an approach would require an excessive count of data records to be managed, which
inherently tends to sever the continuity of data once the part number has been processed.
In order to minimize the number of data records, and to maintain the continuity of data that is needed for responding to special causes
of process variance, the crimping system press or hand tool shall instead be monitored by data coding the measurement and test values
of key characteristics as;
n =5

∑− (X spec − Xi)
X= -(Xspec – Xi); X= i =1 ; and R= max[-(Xspec – Xi ) ] – min[-(Xspec – Xi)]
n
where X= coded data value, Xspec= specified data value, and Xi= measured data value

4.4.2 In-Process Data Collection

Specimens shall be selected in 5 piece sample subgroups and subjected to the requirements of section 3.4 of this specification for all
crimping presses or hand tools used in prototype, pre-launch, rework and production assemblies.
Statistical process control shall be established for each crimping system where;
CCH measurements are monitored with X and R control charts for sample average and range , and
Pull out force tests are monitored with I and MR control charts for individuals and moving range.
The performance of visual inspections shall also be recorded.
Rejects from automatic gaging shall be tallied per crimping system.
4.4.3 Response actions
The crimping process shall be halted and adjustments made when:
SPC charts indicate;
1) one data point is >3σ from the centerline.
2) seven data points in a row are plotted on the same side of the centerline.
3) six data points in a row show increasing or decreasing trends.
4) fourteen data points in a row alternate up and down.
5) two out of three data points in a row are >2σ on the same side of the centerline.
6) four out of five data points in a row are >1σ on the same side of the centerline.
7) fifteen data points in a row are within 1σ of the centerline on either side.
8) eight data points in a row >1σ on either side of the centerline.

Visual inspection indicates;

9) the same process indicator in >60% of the sample.
10) two or more process indicators that total >60% of the sample.
11) two or more process indicators on the same specimens that total >40% of the sample.

5 QUALIFICATION OF CRIMPED ELECTRICAL CONDITIONS

In general, the component supplier is responsible for the design and application requirements of the product and for its manufacture
and reliability. Therefore, the component supplier is also responsible for qualification testing.
The provision of this section is intended for purpose built components that are specifically designed in cooperation with the customer,
or for alternate manufacturers to OEM terminals. Any qualification test protocols derived from this section shall require customer
approval as well as customer acceptance of test results prior to Design Freeze.
The requirements defined in sections 3.4 and 3.5 of this specification shall be met prior to conducting qualification tests of a crimping
system.
Qualification tests shall be planned and the plans documented as a portion PPRD defined in DFM Standard QMS703 of the Corporate
Quality Manual.

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 10 OF 12
Qualification tests shall require evaluation of each wire gauge rating for the components as subjected to:
• RT resistance tests before and after conditioning.
• Cross section analysis before and after conditioning.
• Temperature rise testing before and after conditioning.
Environmental parameters for conditioning shall be defined as part of PPRD for dwell time, test duration and evaluation intervals.
Minimum batch requirements for qualification tests shall be 300pcs, and specimens shall be selected from the 300pc batch at random
by which each member of the population has an equal probability of being selected as part of the sample.

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 11 OF 12
 Terminal Tooling Equipment
controls controls controls

N New
IQC New N Usage New N Maint. New N Maint.
Inspection terminal? crimp Status applicator? Status press? Status
dies?
Y Y Y Y
FIFO
Y
material
control Y QV1 prelim Y N N 750K N
Purpose Purpose
built? dwg built? Threshold? Threshold? Strokes?
required
N N Y Y

OK for QV3 Plan PPRD OK for QV3 Cross Assign Assign

Perform Press
Controls qualification Controls section maint PM maint analysis
evaluation routine routine

Customer
feedback OK for
OK for OK for Crimping
Applicator Press
Station
OK for QV1
Controls

OK for
APQP

OK for TVR

Design N Hold for CD-

Freeze? number

Y
OK for
production
unit

SPC
controls

Tally gaging Y Automatic

rejects Gaging?

Special Y
Halt & adjust
cause(s) with DR-
in SPC?
N

OK for next
process

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Quality Specification CQS001 2.0
8914 Pleasantwood Ave. NW
North Canton, Ohio, 44720
A Crimped Electrical Connections SHEET 12 OF 12