AFCI P/N : 10142344-108KLF

Foreign material presence making difficult mating

06/03/2024

1
Defect description : foreign material presence

Foreign material seems to be plastic residu,

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Analysis of return sample : marks

Similar mark:
same size

Observation of same mark on each side of the connector, made by hollowed cylindrical « tool »
with diam 1,6mm - likely metallic and sharp. – molding ejector diameter is 0,94mm

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Analysis of return sample : particle

1st observation : the particle is easy to remove

because not stuck, only wedged between pin and
housing wall

2nd observation : the particle dimension matches

with tearing off above
→ Around 2 mm in length and 1 mm in width

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Analysis of return sample : conclusion

The particle was generated by a cylindrical and hollowed « tool » - sharp and likely
metallic.
The cutting up was not made with hot tool (plastic not melted)

In AFCI process we didn’t identify any tool our other able to generate this tearing off
and specific mark.

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Looking for potential cause in our molding process

• View of the mold (Ejectors in green color):

3 – No Radius Ejector and

Damage on plastic part is
bigger than all Ejectors

5 – No Radius Ejector

The molding operation can not generate these marks and foreign material

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Looking for potential cause in our molding process

• Positions of parting lines and slider:

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Process description : focus on molding controls

- A visual and dimensional control at the

start of each shift

- A smartscope control at each start of

shift with cavity control

- A check during production every two

hours Pr 07 Fréquence de contrôle
Micro Space HEADER
1 moulée / 2 H
- A visual and smartscope control at the 10142633-XXX
10142393-XXX
end of production 10142343-XXX
10143534-XXX 1 Test Fonctionnel / équipe
10142405-XXX
10169311-XXX
Révision : AD PMOU-001 ANNEXE 1

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Production in progress on 8th of March

• Increased checking frequency = X2

• No anomaly detected in the cavities and nothing broken

• Photos of current cavities:

1 2 3 4

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Process description : full automatic machine

OP 70 Cleaning
System &
OP 20 Lower Pin OP 30 Upper Pin Automatic Tape
OP10 Header
OP15 Row (Pre Row (Pre OP 40 OP 60 and reel
housing loading OP 50 Hold Down
100% Codding Insertion / Final Insertion / Final 100% Hi-pot 100% CCD packaging with
by Bowl Feeder Insertion
check (optionnal) Insertion / Insertion / inspection inspection camera
Bending & Sizing) Bending & Sizing) confirmation
OK OK OK

NOK NOK NOK

Scrap Scrap Scrap Storage

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Process description : focus on controls station

3 cameras control the connector dimensions

In case of dimension out-of-spec, the connector is

automatically ejected.

The cameras are checked at each start of production thanks to

dummy parts

Control Plan →
PCP

©2022 Amphenol Communications Solutions 11

DAE : looking for potential cause in our assy process

Only 2 situations where we « plug » a mechanical part during connector assy.

During bending operations to

maintain the terminals During electrical control

Mechanical part similar to bending

operations.

Our mechanical parts have big chamfer to prevent any damage against connector.
Furthermore, the marks of tearing off doesn’t match with shape of mechanical parts

©2022 Amphenol Communications Solutions 12

©2022 Amphenol Communications Solutions 13