Automated Wiring Systems (AWS) had just won a high-priority contract to supply wire harnesses for large natural gas-powered industrial engines. The deadline was only weeks away, and the order was already changing, including a 50% increase in quantity and additional components for safety stock.
There was one major problem: the military-spec circular connectors AWS needed weren't available from its original distributor or manufacturer.
ElectroShield worked with AWS to identify and validate alternative connectors, coordinate expedited delivery, and establish a longer-term purchasing arrangement.
The result was a solution to the immediate component shortage, along with connector cost savings of as much as 25% on certain components and a blanket purchase order designed around AWS's ongoing demand.
The Challenge of Finding Alternative Electrical Components
Electrical components often have strict specifications or compliance requirements that make sourcing alternatives challenging. Substantial equivalents aren't always readily available, or if they are, they haven't been approved for a specific use case.
Alternative components need to match the original specifications for safety, durability, and performance. This often involves meeting critical standards such as:
- IP ratings for protection against dust, water, or other environmental factors
- Temperature ratings to demonstrate they can operate effectively in extreme heat or cold, especially in harsh environments like industrial or military applications
- Pressure ratings to withstand high-pressure conditions in applications like aerospace or hydraulics
- Application-specific requirements, such as the need to fit within tight spaces, resist vibration, or include specialized coatings to prevent corrosion. Engineers must ensure that any replacement component will seamlessly integrate into the existing system.
Identifying a compatible alternative often requires access to detailed specifications, technical documentation, and manufacturer data. Without these resources, engineers may struggle to determine whether a potential substitute meets all necessary criteria.
Even when an alternative is found, it must be verified to ensure it works as intended in the application. This process takes time and coordination, especially when the timeline is tight.
What Matters When Sourcing an Alternative Connector?
Finding an available connector is only part of the problem. The replacement must also meet the application's technical requirements and be approved before it can be used in production.
Depending on the application, that can mean checking electrical ratings, environmental protection, operating temperature, mechanical compatibility, and other specifications.
Availability and delivery timing matter, too. A technically suitable component won't solve an immediate production shortage if its manufacturer lead time extends beyond the customer's deadline.
That's where working directly with a knowledgeable distributor can make a difference. ElectroShield can work with manufacturers to identify potential alternatives, review component specifications, coordinate customer validation, and determine available sourcing options.
For manufacturers with recurring demand, the next step may also include a stocking program to plan future purchases around expected usage.
How ElectroShield Helped Automated Wiring Systems Meet Their Deadline
The expedited shipment addressed AWS's immediate production needs, but the company also needed a way to manage recurring connector demand.
ElectroShield established a blanket purchase order with scheduled releases based on AWS's usage forecast. Under this arrangement, release dates are planned in advance, and ElectroShield coordinates manufacturer orders ahead of those dates.
The alternative connectors also reduced AWS's component costs by as much as 25% on certain components.
Together, the alternative sourcing solution and scheduled purchasing arrangement helped AWS address its immediate shortage while planning for future production requirements.
Plan for Your Next Component Purchase
AWS's experience demonstrates how alternative component sourcing and planned purchasing can work together.
ElectroShield helped address the company's immediate connector shortage, validated an alternative component, and established a blanket PO with scheduled releases for ongoing demand.
With 50 years in business and more than 60 years of combined tenure across our sales team, ElectroShield works directly with manufacturers to identify components and develop purchasing arrangements around their requirements.
If you're managing recurring connector purchases, we can help you evaluate whether a stocking program makes sense for your operation.
[Read our guide to Circular Connector Stocking Programs]
Send us your part numbers and expected annual usage, and we'll build a stocking program around them.
Contact your ElectroShield representative, email Sales@ElectroShield.com, or call (800) 662-1054.
Frequently Asked Questions (FAQ)
Frequently Asked Questions
How do you know if an alternative electrical connector will work?
An alternative connector must be evaluated against the application's electrical, mechanical, and environmental requirements. Matching a few specifications doesn't automatically make a replacement interchangeable. The component must be validated and approved for the intended application.
How can a blanket purchase order help with future component availability?
A blanket PO establishes planned purchasing quantities and release dates. ElectroShield places manufacturer orders ahead of those dates, with a buffer built into the purchasing schedule. This helps coordinate component availability with anticipated production requirements, although manufacturer lead times still apply.
Can ElectroShield help with both alternative sourcing and ongoing inventory planning?
Yes. ElectroShield can help identify suitable alternative components and establish stocking programs for repeat or forecastable demand. Options include bonded inventory agreements and blanket purchase orders with scheduled releases.
