Teamwork pays off in complex cable market

AWS Electronics is now supplying fully assembled and tested complex cables to General Dynamics United Kingdom (GD UK) for the Bowman communications system.

AWS Electronics is now supplying fully assembled and tested complex cables to General Dynamics United Kingdom (GD UK) for the Bowman communications system.

Bowman was introduced into service in early 2004 and delivers a step-change in capability over the Clansman family of radios through its security, data capability, reliability and resilience against electronic warfare (EW) attack.

In 2002 AWS partnered with industry-leading companies to supply a turnkey solution to GD UK, in direct competition with well-established players in the market.

The AWS-led supply team worked together intensively with GD UK early in the programme to measure up various vehicles' instrument layouts and specify the cables.

This involved substantial up-front investment in expertise that developed optimal solutions for ruggedness, manufacturing and materials costs.

AWS itself invested more than GBP 1 million in equipping an entire workshop, training staff to IPC620 and relevant GD UK and MoD standards, and purchasing stock.

Time and again the team proved that they had not only the expertise that GD UK sought, but also the operational flexibility that enabled them to work proactively with GD UK as both technical and schedule changes multiplied - usually for reasons outside GD UK's control.

As a result AWS expanded their scope of supply on the contract, achieving 99.96% delivered quality performance with 97% on-time deliveries.

Learning from this experience, AWS is working with its world class partners in order to offer similar turnkey solutions in cable and harness manufacture.

In addition to involving different companies on individual projects, the core team now includes: Habia Cable, which offers their expertise in cable technology at both the design and manufacturing stages, and supply cables; Hellermann Tyton, which contributes its expertise with high performance material compounds/adhesives, in heat shrink moulded parts, identification printing systems, clips and cable ties; and Lemo, which contributes its expertise in high density, low weight, electrical and fibre optic connectors for rugged environments.

All three companies have extensive experience worldwide supplying military and aerospace contracts, with all the attendant standards, traceability, ruggedness and approvals.

They have proved themselves frequently by providing outstanding service, pulling out all the stops in support of development, prototyping, approvals and production phases of projects.

This proactivity and responsiveness has enabled AWS to delight customers and win major contracts.

As a team with AWS they provide a dynamic new force in aero/defence assembled cables and harnesses.

Another example of the team's capability is the contract for Westland Helicopters to specify cable assemblies for, and build, land static platforms.

The specifications differed considerably from the vehicle cables.

Again, AWS drew on its partners' expertise in both design and manufacture.

Success in this contract has led (so far) to two major fast response contracts and an order for racks for two naval ships, including layout and cable design to avoid interference and cross-talk.

All these were delivered on time and to high quality, despite very challenging delivery lead times.

For all this success, cable manufacturing is roughly one-third of AWS' business.

The company also assembles PCBs (all types) and full box and cabinet assemblies for various industries including aero/defence, scientific, medical and rail.

The company offers full support from design for manufacture and test, development of test specifications and equipment, lead-free processes, manufacturing to IPC610 Class III standards, customisation, configuration, kitting and logistics.

Beyond this they also have specific expertise in high voltage and radio frequency electronics, undertake repairs (to IPC7710 and 7711), refurbishment, upgrade and reverse engineering.

Thus they provide whole-life support to clients, with outstanding customer focus and service levels.

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