Thermal imaging OEM·Belgium·2020-2021
A European thermal imaging OEM experienced a critical production halt due to high impedance defects in a micro-coaxial cable assembly — the same impedance-verification discipline now applied to every FAKRA program.
- Challenge
- 1,296 out of 2,000 units of AWG #40 CABLINE-VS 1:1 100 mm micro-coax assemblies failed due to high impedance, leading to order cancellation and a major trust deficit.
- Solution
- Halted production and conducted joint technical analysis with the customer's engineering team. Updated test specifications, provided new test reports, manufactured replacement samples, and processed a full replacement order. The corrected impedance verification procedure is now applied to every FAKRA build by default — VSWR sweep on first article before any production lot moves.
- Result
- Successfully resolved the quality complaint, secured a replacement order for the 1,296 defective units, and rolled the verification discipline forward to FAKRA and other RF programs.
Verified specs
- AWG #40 conductor
- 1,296 of 2,000 units rebuilt
- 0 RMA in subsequent year
- Discipline rolled to FAKRA + RF lines
