Start of Production & Crimp Quality at Kabeltechnik: How We Ensure Safety from Day One
September 2, 2025
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Start of Production & Crimp Quality at Kabeltechnik: How We Ensure Safety from Day One
At Kabeltechnik, our focus on quality begins before the first cable is even built. From the early planning phase to final inspection, we apply strict controls to ensure that each crimp, connection and component meets the required standards.
In this post, we want to show two key processes we use to guarantee this:
🔹 CSA – Crimp Section Analysis
🔹 SOP – Start of Production Process
CSA: Crimp Section Analysis
CSA (Crimp Section Analysis) is a destructive test used to check the internal quality of a crimp connection. Once the terminal is crimped onto the cable, we cut it and inspect the cross-section under magnification.
What we check:
- Crimp height and width – must match manufacturer specs
- Copper wire compression – all strands must be fully compacted
- No empty spaces – no air gaps or poor contact
📸 Example from our lab (CSA report dated 21/10/2024):
Result: All measurements met TE manufacturer standards
✔ Crimp height = 0.806 mm (spec: 0.78 ± 0.02)
✔ Widths (CB1/CB2) = OK
SOP: Our Start of Production Process
Before we start producing any cable batch, we follow a full SOP (Standard Operating Procedure) to organize and control every step.
Key steps include:
- Customer Requirements
- Understand specifications, application, and environment
- Understand specifications, application, and environment
- Design & Planning
- Choose proper cable and terminals
- Define lengths, insulation, and special markings
- Production Setup
- Load materials, define tooling
- Apply crimping, labeling, and testing according to design
- Testing & Documentation
- Conduct continuity, insulation, and mechanical tests
- Create test reports and final quality review before packaging
🔧 This process guarantees traceability, repeatability, and full control from start to finish.
Final Outcome: Certified and Reliable Connections
By combining a well-documented SOP with CSA quality testing, we can confidently guarantee:
- Safe mechanical connections
- Reliable current transmission
- Compliance with OEM and Tier 1 specs
Every crimped connection is backed by process control, test data, and engineering validation. That’s our commitment to quality.
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