Ultrasonic splicing technology from Sonobond Ultrasonics has significantly reduced production time for a major manufacturer of automotive wire harnesses. Curt Reynolds, director of manufacturing at J & M Products in San Fernando, CA reports that his company has cut splicing time by a dramatic 60% since installing Sonobond's SpliceRite™ wire splicers.
An Alternative to Mechanical Banding
Prior to introducing Sonobond ultrasonic splicing technology into its production process, J & M Products used a two-stage system of mechanical banding and soldering.
"This system had several problems," according to Reynolds. "Wires would sometimes become separated. It could also be difficult to get the skilled people we needed to do the work. That's why we began looking for a more cost-effective method." With approximately 25 years in the industry prior to joining J & M in 2001, Reynolds realized that ultrasonic splicing might be a viable alternative and began to investigate.
A Practical, Cost-Effective Solution
It quickly became apparent that the Sonobond SpliceRite™ Ultrasonic Wire Splicer offered J & M Products the practical, cost-effective solution it needed for faster, more reliable wiring harness assembly. The company's research showed that this proven ultrasonic technology quickly splices wire bundles and creates a true metallurgical bond -- without producing arcs, sparks, or fumes. J & M Products also liked the fact that this Sonobond system eliminates any need to crimp, clip, solder, or dip in order to make strong, high-quality wire connections. And, unlike other ultrasonic welders, the SpliceRite is able to bond wire bundles even if the wires are oxidized or tin plated.
The SpliceRite comes in both 1,500 and 2,500 W capacity and utilizes Sonobond's patented Wedge-Reed system of high vibratory force and low amplitude coupling. Welds can be controlled by height, energy, or time. The unit's microprocessor, which is able to interface with a computer via RS232 port, can also store and recall up to 250 jobs.
Effective & Easy to Operate
The decision by J & M Products to install the SpliceRite began to pay off immediately.
"We realized within minutes that the SpliceRite was the right choice for us," says Reynolds. "We reduced splicing time by a good 60%. There is simply no comparison between our SpliceRite machines and the technology we used before. We are very pleased with all three SpliceRite units we installed."
Reynolds also reports that the Sonobond system is simple to operate. "Once the SpliceRite is set up, it is primarily just a matter of pushing a button. Minimal operator training is required, and stored jobs are locked out from operator adjustment. We no longer need to find people with the special skills required for soldering."
Positive Results
The proof of any manufacturing technology is in the finished product it produces. Reynolds reports that J & M Products is very pleased with the high-quality results they get from their Sonobond equipment. Since introducing the SpliceRite into the production process, warranty claims resulting from loose wires or poor splices have become essentially nonexistent.
In addition, Reynolds says that J & M Products is especially pleased with Sonobond's customer service.
"If we need something or have questions, they get right on it," he says. "Some other equipment manufacturers aren't as willing to respond to service needs once their equipment is in the door. But Sonobond is different. Not only is their technology great, but their service is first-rate. It's another reason why we are very pleased with our choice to install Sonobond's wire-splicing equipment."
