CUSTOMER PROBLEM:
A leading sheet metal manufacturer was battling repeated cable failures in a high-demand production environment. Their existing solution—a plastic-jacketed cable housed in a hydraulic hose with non-environmental-rated connectors—was not only difficult to manage but was also highly susceptible to degradation. The cables were exposed to oil and cutting fluids, which caused them to stiffen and fail prematurely.
The non-environmental connectors also made the setup prone to contamination and mechanical wear, contributing to significant downtime and constant replacements. Over a two-year period, this customer was forced to replace the cable assembly six times per unit—leading to lost production time, increased labor, and high replacement costs.
Amphenol TPC Wire & Cable’s Solution
Engineered for Performance and Built to Last
Recognizing the harsh conditions and the need for long-term reliability, Amphenol TPC Wire & Cable’s engineering team developed a custom cable assembly tailored to the specific challenges of the customer’s tooling machines. The solution included:
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Trex-Onics® 22 AWG Cable with 18 Shielded Pairs: Engineered with a durable polyurethane jacket that resists oil, chemicals, and abrasion.
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Stainless Steel Braid Shielding: Added reinforcement to withstand mechanical stress and enhance protection against sharp metal edges and external abrasion.
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Heavy-Duty Locking Connectors (HDLC): Rugged, IP67-rated connectors capable of withstanding environmental submersion, ensuring a secure and contamination-resistant connection.
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Custom Lengths and Configurations: The assembly was custom-built to fit the customer’s exact machine layout, eliminating slack and improving cable routing.
This wasn’t just a product replacement—it was a purpose-built solution that solved a long-standing operational problem with a durable, plug-and-play design.
Customer Results: $318,000 Saved and 384 Hours of Downtime Eliminated
The custom ATPC assembly was installed in 12 production units, each of which previously required six replacements over two years. With ATPC’s solution, the cables remained in service without failure for a full 24-month cycle—reducing maintenance touchpoints and keeping machines running without interruption.
Results at a Glance:
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$318,000+ in Material and Labor Savings
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384 Hours of Production Time Recovered
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Improved Reliability in Oil-Heavy Environments
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Simplified Maintenance with Field-Rated IP67 Connectors
By partnering with Amphenol TPC Wire & Cable, the customer gained more than just a longer-lasting cable—they gained a custom-engineered solution that directly improved their bottom line and freed up valuable maintenance resources.
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