7 Reasons Why Safety Cable Trumps Lock Wire

March 21, 2017 News

There has been much discussion revolving around lock wire and safety cable, and which reigns supreme. Through our own due diligence, we’ve determined that using lock wire to retain fasteners is time consuming and error prone, which makes it costly. Lockwire also requires extensive training and produces sharp ends when cut, which can cause serious injury to the technician.

Meanwhile, extensive research and testing at GE Aircraft Engine facilities revealed that the use of Bergen Safety Cable instead of lockwire resulted in a 50 percent reduction in installation time with consistently superior quality and lower assembly costs.

In today’s manufacturing environment, speed and quality are everything. Here are a few reasons why Bergen Safety Cable is superior to lock wire.

7 Major Benefits of the Bergen Safety Cable System:

  1. Reduction of potential foreign object damage

    When traditional lock wire is removed from an application, it needs to be cut many times in order to be completely removed. This process produces numerous small fragments which are difficult to keep track of. If the scrap material cannot be fully recovered, it can cause serious damage to the aircraft and potentially its passengers as well. This is known as foreign object damage or FOD. However, when Bergen Safety Cable is removed, it produces only two pieces of scrap, making it easy to keep track of and eliminates the potential for FOD.

  2. Improved access to tight areas

    The Bergen Safety Cable tool was designed specifically to allow access to restricted areas. The short length of the tool as well as the tool nose, which can be rotated 360 degrees, assists operators working in these tough conditions.

  3. Elimination of guesswork

    Using traditional lock wire requires that the operator determine how much wire to use, how many twists per inch, and many other important details. If a step is missed or completed incorrectly using lock wire, the operator must start all over. With Bergen’s Safety Cable system, all the guesswork is eliminated. The operator simply strings the cable through the fastener holes and the safety cable tool does the rest, which results in perfectly wired fasteners every time and increased production.

  4. Minimal training required

    The cumbersome nature of applying traditional lock wire can take a very long time to master. With the streamlined method of the Bergen Safety Cable system, a new operator with zero experience can be up and running within 30 minutes.

  5. Eliminates injuries

    Traditional lock wire produces very sharp ends when cut, which poses a serious threat of injury to the operator. The fused ends and flexible nature of Bergen Safety Cable removes the risk of injury 100 percent.

  6. User-friendly tooling

    The Bergen Safety Cable tool was designed with the user in mind. Our tool utilizes the best principles of ergonomics, which allows the tool to fit comfortably in the operator’s hand.

  7. High return on investment

    Using the Bergen Safety Cable system simplifies the task of lock wiring fasteners together. The simplicity translates into time savings, which allows an operator to complete a job in half the time. The time savings allows the operator to move on to the next project faster, which can double production.

Other benefits include reduced inspection time, consistent cable tension on each application, and a material that is lighter than lock wire and traditional safety wire. Choosing to use Bergen Safety has a myriad of significant benefits that our customers agree improve product quality and save them time and money across the board.

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