Complex Cable Harness Reverse Engineering and Production Process Development and Validation – Phase II

Cables can be found just about anywhere, and the integrity of a cable has a profound effect on its ability to do its job and to public wellbeing and safety. Deteriorating and aging cables that need replacing are a growing concern, but simply amassing and storing varieties of cables – which might not even fulfill the specific requirements – does not solve the problem. Instead, reverse engineering specific cables provides a faster, better solution to building just what is needed for a specific project.

Phase I delivered a total of 650 each of the CABLE ASSEMBLY, SPECIAL PURPOSE ELEC (P/N C3-305), NIIN 01-565-7978 for First Article Inspection (FAI) and produced 650 cables to support Low Rate Initial Production (LRIP). However, issues with the cable related to the design (this is a reverse engineering project, not a redesign) emerged. Current MPN and configuration variation under -7978 NIIN has caused field issues with serviceability and troubleshooting, since inline fuse is inaccessible on many of the configs. In Phase II, more samples are needed to establish confidence in LRIP capability. Since defects are already present, a solid run of “no trouble found” conditions are needed to establish confidence in LRIP capability (i.e. only 1 defect allowed in 1,000,000 parts to reach six sigma).

Those interested in participating in this initiative should contact Tony Haynes at or (734) 730-0759 within 90 days of this project announcement. We encourage participation of Disadvantaged Business Enterprises (DBEs), including Minority Business Enterprises (MBEs) and Women’s Business Enterprises (WBEs).