Manufacturer Decreased Cable Assembly Defects By 80% With Kure
Project Summary
The problem: A manufacturer was experiencing a growing number of cable assembly defects that were increasing scrap, driving rework, and slowing production efficiency.
By using Kure’s structured process improvement tools and AI-guided workflows, the organization reduced average open circuit defects from 6.5 defects per week to 1.3 defects per week, achieving an 80% improvement in quality performance and process consistency.
Introduction
In precision manufacturing environments, even small process inconsistencies can create major operational challenges. For this organization, cable assembly defects were increasing material waste, creating additional rework, and putting pressure on production schedules.
The team used Kure to better understand the problem, organize improvement efforts, and identify the root causes driving the defects. Through Kure’s guided workflows and centralized improvement tools, the organization was able to simplify the process, reduce variation, and implement sustainable improvements more efficiently.
The project also reflected the principles of Ethical Efficiency™, focusing not only on improving operational performance, but also on creating a more reliable and repeatable process that better supported employees and long-term success.
The Problem
The production team was experiencing a high number of open circuit defects in cable assemblies. These defects became the leading contributor to scrap throughout the year, increasing waste, rework, and production costs.
An open circuit defect meant the electrical connection inside the cable assembly was incomplete, making the final product unusable. As defects increased, the organization faced growing pressure to maintain production schedules while also managing higher levels of inefficiency and material loss.
For manufacturing organizations, process improvement is essential to maintaining quality, controlling costs, and delivering reliable products. The team recognized that reducing process variation and improving standardization would be critical to improving overall performance.
The Root Causes
Using Kure to analyze the process and organize findings, the team identified several key contributors to the defects.
First, process documentation allowed for two different tinning methods. Because operators were using different approaches, the process lacked consistency and introduced variation into the final product.
Second, the existing tinning process required operators to heat the solder cup with an iron while manually feeding solder into the connection. This created inconsistent wire encapsulation inside the hot shoe, impacting connection quality.
The team also discovered that the cable strip length did not properly account for the bend radius required to correctly position the wires inside the solder cup. This made it more difficult to create strong and reliable electrical connections during assembly.
The Solutions
Using Kure’s structured improvement approach, the team implemented two targeted solutions that directly addressed the root causes.
Adjusted Cable Strip Length: The cable strip length was modified to better support the required bend radius. This allowed the wires to sit more effectively within the solder cup and improved overall connection quality.
Standardized the Tinning Process: The organization updated process documentation to define one standardized tinning method for all operators. This reduced variation and improved process consistency across production.
While the improvements were straightforward, they created meaningful operational impact by stabilizing the process and improving reliability.
The Results
The improvements produced immediate and measurable results.
Average open circuit defects decreased from 6.5 defects per week to 1.3 defects per week, resulting in an 80% reduction in defects.
The process also became significantly more stable after implementation, improving consistency across production operations.
As defect levels decreased, the organization experienced lower scrap and rework rates, smoother production flow, and greater confidence in process reliability. Operators were able to follow a clearer and more repeatable process, helping improve quality outcomes throughout production.
Conclusion
This project demonstrates how focused process improvement efforts can drive meaningful manufacturing results when teams have the right structure, visibility, and tools in place.
By using Kure to organize improvement work, identify root causes, and implement targeted solutions, the organization successfully reduced defects, improved process consistency, and strengthened operational performance.
The project also reinforced the value of Ethical Efficiency™ by showing how sustainable improvements can support both business performance and the employee experience. With a more stable and reliable process now in place, the organization is well positioned to continue reducing waste, improving quality, and scaling operational excellence.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
