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Real manufacturing dilemma: “Our company depends on the manual assembly of over 500,000 electrical components, with an estimated 2.5% defect rate, and currently faces difficulties in scaling our operations. Since we have been asked by management to implement an automated production line, we need help in determining how to begin the process (i.e., type of […]

Real production challenge: The Production Manager at a leading MCB manufacturer stated that their manual silver contact welding failed at a rate of 1.2% because of inconsistent heat and pressure. To solve this problem they needed to find an automated, repeatable solution that met IEC standard requirements, and would therefore reduce rework expense. Choosing a […]

Real quality pain point: “Our trading company bought an ‘universal’ test bench for a 400A MCCB long time test. However, it did not have the ability to stabilize the current, resulting in 15% error rate and therefore rendering it completely useless for IEC 60947-2 compliance testing. The expenditure was $25,000 and 4 months of effort […]

Real sourcing challenge: “We needed a fully automated line for Type 2 SPDs, but many suppliers only offered semi‑automatic assembly benches. One manufacturer didn’t even have experience with varistor soldering. After visiting five factories, we finally found a reliable partner who understood the need for precision welding and in‑line electrical testing.” — Production director, a […]

Real production headache: During the final testing phase, we were rejecting 8% of our MCBs due to thermal trip drift. The reason for the issue with the MCB’s circuit was that the calibration bench that we were using did not hold stable current for time periods greater than 30 minutes. There was no way to […]

Real sourcing challenge: “We traveled to China to see three different MCB automation vendors. The first vendor had a very large 30-meter line with a cost of $1M. This is way too large for our plant; it would not fit in our building. The second vendor had a benchtop unit that manufactured one MCB at […]