Dear QC Supervisor,

For years, our company has been a “behind the scenes” contributor to users of magnet wire as a supplier of on-line test equipment to the manufacturers of the wire. Perhaps your company is now considered a preferred (and picky) customer and your wire is already made on lines equipped with the Lear Fusion System. If so, be assured that your wire is the most thoroughly tested available.

We supply equipment, worldwide, that continuously tests the enamel surface quality of magnet wire as it is being manufactured. On lines equipped with our Fusion System, the enamel is tested, end to end, for beads, blisters, roughness, insulation weakness, pinholes, and bare wire. The operator is continually aware of these test results and trends as the wire is accumulating on the spool, allowing him to take corrective action to avoid out-of-spec conditions. The system then generates a detailed completed report of these results on a per foot (or meter) basis as the next spool is filling.

The operator, using the immediate feedback of performance data, simply learns to make better wire, consistently. He knows that it will meet your quality standards.

Everybody wins. You get better wire, and fewer quality headaches, and he generates less scrap since he can correct trends before they lead to unshippable wire. If the trend cannot be reversed, he can collect the bad wire on a scrap spool until the problem can be fixed rather than to continue manufacturing (and shipping) wire that you will return (if you can catch it in time to prevent it from being used in your products).

As said earlier, you win because your product failures due to problems with the wire will be reduced. Your supplier wins twice. First, when he makes better wire with less scrap, according to his specs and, second when you don't return a truckload of bad wire, according to your specs and some bad experiences.

If your wire doesn't always meet spec, it might be a good idea to ask your supplier if wire could be switched over to lines using the LEAR FUSION SYSTEM.

Sincerely:

LEAR ENGINEERING CORP