01
Problem
Flexible cable assemblies required a repeatable overall-length measurement method that minimized operator technique variation and ensured fit in final assembly.
02
Constraints
- Cable flexibility introduced routing and tension-related measurement variation.
- Long assemblies required practical measurement methods without damaging product.
- Multiple operators had to generate reproducible results.
- The method had to remain fast enough for production use.
03
Engineering Decisions
- Defined a fixture-controlled routing path and zero-point reference.
- Specified measurement technique and tension limits.
- Used variable Gage R&R to quantify method error.
- Created periodic fixture verification requirements.
04
Validation
- Measured selected samples across operators and trials.
- Analyzed repeatability and reproducibility using ANOVA methods.
- Compared method variation to tolerance requirements.
05
Risk & Mitigation
- Cable stretch could bias results; mitigated with defined tension technique.
- Parallax error could affect readings; mitigated with stops and clear indexing.
- Fixture wear could affect routing; mitigated with verification intervals.
06
Outcome
The measurement method was validated as a repeatable production inspection method for cable length acceptance.