Specification Changes & Flexible Adjustments
Specification Changes & Flexible Adjustments
Finding after sampling that a cable length needs adjusting, a wiring sequence has to change, or even a connector part number needs replacing is common during development. SyncTronics assesses the real impact based on when the change is raised, works first on returning or reallocating existing material, and reissues the drawing for confirmation, keeping disruption to the project as low as possible.
One point to be clear about upfront: the earlier a change is raised, the more room there is to handle it. The actual impact depends on how far material purchasing and production have progressed.
When Changes Usually Arise
The period after the first sample build and before pilot production starts is where changes concentrate. It is also the best time for them, since material has generally not been committed in volume.
Changes raised during pilot production are less common but still happen. In those cases the approach has to be assessed against production progress.
What Gets Changed Most Often
Cable length. The most frequent and the most straightforward. As long as material has not been cut, the adjustment has almost no knock-on effect.
Wiring sequence. Second most common, usually driven by circuit revisions on the design side. Once changed, we build exactly to the specified wiring sequence.
Connector part number. The most troublesome of the three. When it changes after an order is placed, connectors already purchased may no longer be usable and need separate handling.
How Each Stage Is Handled
|
Timing of change |
Actual impact |
How it is handled |
|
Material not yet purchased |
Almost none |
Specification and drawing updated directly |
|
Material received, production not started |
Material may sit idle |
Return or exchange negotiated with the supplier first; alternatively, complete the current batch with existing material |
|
Production partially complete |
Completed units cannot be changed |
Production paused, completed and remaining quantities counted, handling of completed units discussed |
|
Complete and awaiting shipment |
Rework required |
Product recalled and rework feasibility assessed, such as removing connectors and rebuilding |
One practical limit on rework deserves attention. Removing a connector and re-crimping shortens the cable slightly. If the original design carries a tight length tolerance, the reworked product may no longer meet the specification, and we confirm and flag this in advance. Some cables and custom connectors cannot be disassembled for rework at all, and those cases have to be assessed separately.
How Existing Material Is Handled
Material is handled in a set order of priority, with the aim of limiting your loss as far as possible:
- Return to the supplier
- Exchange with the supplier for the parts the revised specification requires
- Complete the current batch with the original part number, introducing the change from the next batch
- Reallocate to another project, including other customers or industry partners
- Remaining material taken over by the customer
The first four all avoid material becoming dead stock. Only when none of those routes works does the fifth apply, and that is discussed with you in advance.
Drawings Require Re-approval
Every specification change requires a reissued drawing and fresh approval, regardless of how small the change is.
The reason is that the drawing serves as the basis for two things at once: our shipping standard and your acceptance standard. If it is not updated in step, the two sides end up judging conformance differently. A 5mm length adjustment and a connector replacement follow the same process.
Lead Time Impact
There is no fixed answer, as it depends on the stage at which the change arises.
A practical way to estimate is to treat the revised work as a fresh build and then add or subtract roughly a week. Where disassembly and rework are needed, it can take longer than building new. Where the change is a specification adjustment before production starts, the impact is comparatively limited.
Where Changes Cannot Be Accommodated
When a product is already complete and involves cables or custom connectors that cannot be disassembled for rework, the change is not technically feasible. Material for these products is usually specific enough that it cannot readily be used elsewhere.
In these cases our recommendation is to use the current batch as built, and introduce the new design from the following batch. This avoids wasting material already committed and gives the revised specification a full window for confirmation and verification.
Information Worth Providing With a Change Request
- The specific items changing and the new specification
- Original drawing number or part number
- Reason for the change, which helps identify whether other options exist
- Whether the current batch should change as well, or the change starts from the next batch
- Any delivery constraints
Related Products & Technical Resources
If you are currently arranging prototype builds, adjusting specifications, or coordinating delivery, the following may help:
High-Mix Low-Volume Project Support | NPI & MOQ | SyncTronics Technology
Wire Harness Assembly | Custom Wire Harness & Cable Assembly | SyncTronics Technology
Need to Adjust a Confirmed Specification?
Send us the items changing and the new specification. SyncTronics will first confirm where material and production currently stand, assess the workable approach and lead time impact, then reissue the drawing for your approval.
Need Wire Harnesses, Connectors, Electromechanical Components, or Custom Solutions? Contact Us Today
Whether you are looking for connectors, cables, wire harness assemblies, electromechanical components, or complete electronic interconnect solutions, SyncTronics provides professional technical support and engineering evaluation for product selection, specification verification, New Product Introduction (NPI), OEM/ODM customization, as well as high-speed transmission, high-reliability, and other specialized application requirements.
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