Ergonomic Guide to a Safer, More Efficient Connector-Assembly Workplace

• Published in: Appliance Design Vol. 67; no. 2; pp. 34 - 36
• Main Authors: Erickson, David, Connors, Jim
• Format: Trade Publication Article
• Language: English
• Published: Troy BNP Media 01-02-2019
• Subjects: Appliances; Assembly; Automation; Best practice; Connectors; Design; Housings; Human error; Jamming; Keying; Manufacturers; Manufacturing; Product design; Redesign; Sensory feedback; Wire; Workers
• EISSN: 2328-1219
• ISSN: 1552-5937

Newer designs offer benefits that may include: * employing adequate and safe push points for leverage during the connector-mating process; * giving an audible "click" and tactile feedback when the connector is engaged so production workers know when to stop applying force; and/or * providing a visual key to avoid jamming connectors together in the wrong orientation, such as rounded edges on housings and lead in of connectors to further reduce assembly issues. Beneficial connector features include: * offering connector and terminal polarization so workers can perform mating and assembly in only one orientation; * offering keying options and multiple connector color options in situations where mating multiple connectors of the same position size may create confusion; * providing an audible and tactile feel that lets assemblers know the connector halves have been fully mated; and/or * using a terminal position assurance (TPA) device to improve alignment of the terminal in the connector housing, which results in less chance of terminal stubbing as well as reducing mating forces. A knowledgeable connector supplier can help by: * gathering and evaluating insight about product design challenges and operations on the manufacturing floor; * objectively observing and documenting how workers assemble connectors; * seeking feedback from assembly line workers about the assembly process for possible ways to reduce stress and errors; * comparing those observations with manufacturing production failure logs; and/or * crafting recommended changes for connector redesign and/or ergonomic workspace improvements.