A medium-sized machinery manufacturer in Germany, employing 450 people, produces automated assembly lines for the automotive industry. Their equipment operates 24/7 in harsh factory environments with high vibration, dust, and temperature fluctuations. The company had been using standard junction boxes and terminal blocks for electrical connections, but reliability issues were affecting production uptime.
Electrical connection failures were the leading cause of machine downtime. Over a six-month period, the manufacturer recorded 47 unplanned stoppages traced to junction box problems: moisture ingress corroded terminals, vibration loosened wire connections, and dust accumulation caused shorts. Each stoppage cost an average of $2,800 in lost production and repair labor. Annual losses exceeded $130,000.
Traditional IP54 boxes could not keep out fine metal dust. Technicians had to re-torque connections every two weeks. The company tried silicone sealants and aftermarket gaskets, but these degraded within months and required constant reapplication.
The maintenance team assessed three suppliers. Singi Cable's case stood out because of its IP67 rating, which guaranteed dust-tight and temporary immersion protection. The double-wall design with silicone gasket provided a reliable seal without additional sealants. Stainless steel hardware resisted corrosion. Most, the cases complied with IEC 60947-1 (low-volt-level switchgear and controlgear) and UL 489 standards, which the manufacturer required for CE marking. The one-piece construction reduced installation time by 40% compared to multi-part enclosures.
The project spanned four weeks. In week one, the team conducted a site survey and identified 38 critical junction points across three production lines. In week two, they ordered custom configurations with pre-punched cable entry holes and integrated strain reliefs. Week three involved phased replacement: one production line was retrofitted during a scheduled shutdown. The main challenge was fitting existing cables with different diameters inside the case. Singi's technical support recommended using multi-diameter cable glands available as accessories. After a brief adjustment, all connections fit securely. Week four completed the remaining two lines.
Six months after replacement, electrical fault-related downtime dropped from 47 incidents to 19—a 60% reduction. Annual savings reached $78,000 from fewer stoppages and reduced rework. Cable connection maintenance time fell from 12 hours per month to 2 hours. The sealed cases also eliminated corrosion-related component replacements, saving an additional $8,400 per year. Overall equipment effectiveness (OEE) improved by 4 percentage points on the affected lines.
"Switching to Singi Cable cases was the most straightforward reliability upgrade we ever made. The IP67 seal solved our dust and moisture problems completely, and the integrated strain relief meant no more loose wires. Our maintenance team has been freed up to focus on preventive tasks instead of emergency repairs." — Plant Maintenance Manager
Choose the right ingress protection early. The manufacturer underestimated the aggressiveness of metal dust. Choosing IP67 from the start would have avoided the cost of interim fixes.
Standardize on a single case family. Using a uniform platform reduced spare parts inventory and simplified training. The same case now serves for all control cabinets and field junction points.
Engage supplier technical support during design. Singi's guidance on cable gland choice prevented cable compatibility issues that could have delayed the rollout.
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