Scaling Cable Assemblies from Prototype to Volume Production Without Quality Drift

Scaling cable assemblies from prototype to volume production introduces new challenges in consistency, documentation, materials, cost control, and manufacturability. Without the right processes, OEMs often experience quality drift which are subtle variations that accumulate into performance issues, field failures, or certification setbacks.

This guide explains how to prevent quality drift and achieve repeatable, stable cable production across global sites.

Scaling Cable Assemblies: Why Quality Drift Happens During Scale-Up

Common root causes include:

• Varying workforce skill levels
• Inconsistent work instructions
• Tooling changes
• Unapproved material substitutions
• Connector sourcing variations
• Inadequate prototype documentation

These issues multiply when scaling across regions.

Establishing a Repeatable Manufacturing Workflow

Golden Samples & First Article Inspection (FAI)

A validated golden sample becomes the benchmark for every production run.First Article Inspection verifies:

• Dimensional accuracy
• Connector orientation
• Termination quality
• Shielding and grounding
• Routing consistency