CableDataSheet, Cable and Wire Technical Consulting Service

Fajar Cables Sdn Bhd.

Fajar Cables Sdn Bhd is an ISO 9001:2008 certified company based in Selangor, Malaysia.

We manufacture a variety of electrical wires from flexible cables and auto cables to welding cables and multi-core control cables.

We are a member of the Malaysian Cable Manufacturers Association (MCMA) and the Electrical and Electronics Association of Malaysia (TEEAM). Our products are approved by the Energy Commission of Malaysia (Suruhanjaya Tenaga) as well as the Standards and Industrial Research Institute of Malaysia (SIRIM).

The care that we put into our products begin with the procurement of quality raw materials. As a proud supporter of the local manufacturing industry, all of our raw materials are sourced from reputable Malaysian companies. Our products are then manufactured using stringent and meticulous production processes, after which they are put through rigorous pre- and post-production tests and quality checks to ensure that the finished goods conform to the highest standards.

With over 20 years of experience behind us, Fajar Cables is at the forefront of the Malaysian cable manufacturing industry. Our broad customer base, continued success and persistent progress are testaments to that.

Company History

Fajar Cables Sdn Bhd began its operations in 1988, initially comprising a single factory lot. A testing facility was set up in 1989, and in 1993 we acquired a neighbouring factory lot. With the additional floor space, we purchased additional machines and equipment in order to increase both our production capacity and product range. The new machines also enabled us to significantly reduce our production lead time.

In 1996, we obtained the MS 140 certification from SIRIM QAS Sdn Bhd, Malaysia's certification, inspection and testing body. The MS 140 certification applies to flexible cables with nominal cross-sectional conductor areas between 0.5mm² and 2.5mm². This was followed by the MS 136 certification in 2000, which applies to single core cables with nominal cross-sectional conductor areas between 1.5mm² and 70mm².

Also in 2000, we obtained the MS ISO 9002:1994 Quality Management System (QMS) certification. This certification recognises Fajar Cables' success in the implementation of a structured management system which helps us to consistently meet customer and regulatory requirements while achieving continual improvement of our processes. In a year's time this would be further upgraded to the MS ISO 9001:2000 certification. As of 2009, our QMS system is compliant with the ISO 9001:2008 certification.



Manufacturing Process

Drawing



The first step in the process of cable manufacturing is wire drawing. Copper rods received from the supplier are too thick for usage in flexible wires so they will have to be stripped down to the required diameter. To do this, they are pulled through a series of dies of decreasing sizes. Copper wires will emerge once the desired diameter is reached. The wires then go through an annealer where they are refined to obtain better electrical conductivity. Once complete the wires are packed onto metal bobbins.

Bunching



The next step after drawing is wire bunching. This is where the copper wires are twisted together to form a cable. The number of wires twisted together determines the nominal cross-sectional area of the cable. Bunching a series of thin wires together provides more flexibility than solid wires of similar size.

Stranding



Stranding is basically similar to bunching; the only difference here is that stranding refers to the twisting of insulated cables while bunching is reserved for bare copper wires. For certain types of flexible cords, this is where the insulated cables are twisted together with cotton yarn before going through a final extrusion process.

Extrusion



Extrusion is the process where the bare copper cables are insulated. Depending on product requirements, the cables may have to go through the extrusion stage more than once, for example if the cables require additional sheathing on top of its insulation.

Coiling and packing



The final manufacturing stage involves coiling and cutting the cables to its required packing length. The cables can be packed onto drums or as individual rolls, after which they are wrapped, labelled and stored while awaiting shipment.
   
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