Xico
Resolving Crimp Quality Issues for Xico
This customer was having a quality concern with an existing vendor. A crimp pin that was not the correct size for the raw cable was being double crimped. Our engineering team was able to pinpoint a process cause and ensure a higher quality outcome by finding the correct crimp for the application. We were also able to offer partial quick turn deliveries avoiding any line down issues.
The Challenge
Xico, a manufacturer known for precision-engineered lighting systems, encountered a critical issue with an existing supplier. A crimp pin used in their cable assemblies was not properly matched to the raw cable size, resulting in the need for double crimping to hold connections in place. This process inconsistency raised quality concerns and created the risk of failure in the field. In a highly competitive industry where performance and reliability are non-negotiable, Xico needed a fast and permanent solution to restore quality and avoid potential line stoppages.
The Solution
AI Cables USA was brought in to investigate and resolve the issue. Our engineering team conducted a detailed process review and quickly identified the root cause: the crimp pin being used was not correctly sized for the specific cable application.
Correcting the Crimp Specification
We sourced and tested a properly sized crimp that was fully compatible with the raw cable. This change allowed for a single, precise crimp that met both mechanical and electrical standards, improving the consistency and overall reliability of the assembly.
Quick-Turn Partial Deliveries
In addition to solving the technical issue, we helped Xico avoid potential production delays by offering partial quick-turn deliveries. This allowed their manufacturing lines to stay operational while we scaled up full production with the new specifications.
Project Outcomes
Our collaboration with Xico resulted in:
- Identification and correction of a critical process flaw
- Improved assembly quality and reduced failure risk
- On-time, partial deliveries that prevented any line-down scenarios
- Strengthened supplier relationship through proactive communication and technical support
Capabilities Demonstrated
This project demonstrates the core strengths of AI Cables USA:
- Engineering analysis and process troubleshooting
- Sourcing and implementing application-specific crimp solutions
- Flexible production and delivery options
- Responsiveness to urgent quality and supply chain concerns
We support clients not just with manufacturing, but with the technical insight and supply chain agility required to maintain operational continuity.
Ready to Eliminate Your Production Bottlenecks?
AI Cables USA combines engineering expertise with high-quality manufacturing to help you solve complex cable and connector challenges. If you’re facing recurring quality issues or vendor inconsistencies, we’re ready to help you improve product performance and reduce risk.