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Where Complex Products Are Engineered, Built, And Delivered
Your end-to-end EMS partner from concept and design to prototyping and mass production
Trusted by 100+ clients across 4 continents for over 25 years
Trusted by teams that can't afford failure
25
+
Years of Experience
100
+
Clients worldwide
6
+
Industries served
ISO
9001 & 14001 certified
One Partner For Every Electronics Manufacturing Need
  • 25+ years
    Decades of cross-industry manufacturing expertise so your project benefits from lessons already learned.
  • Fast time to market
    Dedicated NPI resources and quick-turn support to launch your product faster without cutting corners.
  • Truly one-roof
    EMS, wire harnessing, box build, testing - all under one roof. Fewer vendors, cleaner accountability.
  • 100+ clients worldwide
    A global client base spanning consumer electronics, automotive, medical, telecom, and renewable energy.
  • Reliability & quality
    ISO 9001 & 14001 certified with multi-stage inspection delivering consistent quality, every run.
Everything You Need. Under One Roof.
Design &
engineering
Design engineering, DFM consulting, and rapid prototyping to take your idea from concept to a production-ready design.
Electronic Manufacturing
Services
Full electronics manufacturing services - SMT, through-hole, and mixed-technology assembly with complete traceability and IPC-compliant processes at every stage.
Cable & wire harness
manufacturing (assembly)
Custom cable and wire harness assemblies engineered for precision, durability, and compliance from single prototypes to high-volume runs.
Testing & validation
In-circuit testing, functional testing, and burn-in processes to ensure every unit meets spec before it ships.
Box build
Complete box-build assembly integrating PCBs, harnesses, mechanical parts, and enclosures into a fully tested, field-ready end product.
NPI support
A dedicated resource to manage new product introductions and fast-tracking your time to market without compromising quality.
Built For Precision-Critical Environments
We serve industries where failure is not an option - delivering the reliability, compliance, and engineering rigour each sector demands.
Consumer Electronics
High-volume, high-speed assembly with the cosmetic and functional consistency that consumer products demand.
Automotive
IPC Class 3 quality, full traceability, and wire harness assemblies engineered to withstand harsh in-vehicle environments.
Medical Devices
Precision manufacturing with strict compliance, cleanroom-compatible processes, and documentation standards for regulated environments.
Telecom
Reliable, high-density assemblies for network infrastructure and communication hardware where uptime is everything.
Renewable Energy
Durable electronics and wire harness solutions built for the thermal and environmental demands of solar, wind, and energy storage systems.
Industrial
Ruggedised assemblies and custom harnesses designed for continuous operation in demanding factory and field environments.
We Serve 13+ Industries From Aerospace To Defence To Smart Infrastructure.
From Your Idea To The Final Product With Complete Visibility At Every Step
We don't just execute, we partner. At every stage, your dedicated JINST team brings engineering input, proactive communication, and full traceability so you're never in the dark.
Concept & Requirement Gathering
We begin by understanding your product, application, volume targets, and quality requirements. Our engineering team reviews your design files, flags potential manufacturability issues early, and aligns on timelines before a single component is ordered.
Prototyping
We build your first units fast with our quick-turn prototyping capability and dedicated NPI resource. You get a physical product to evaluate, test, and refine before committing to full production.
Production
Once the design is locked, we move into full-scale manufacturing (PCB assembly, wire harnessing, box build, and global component sourcing) all under one roof. Our SMT lines and ESD-controlled environment ensure every unit is built to spec, every time.
Testing & Validation
Every unit goes through our multi-stage inspection and testing protocol in-circuit testing, functional testing, AOI, and X-ray where required. Nothing ships until it passes. Full traceability records are maintained throughout.
Delivery
Your product ships on time, fully documented, and ready for the field. We manage packaging, labelling, and logistics coordination and stay available post-delivery for any support your team needs.
Problems Solved. Outcomes Delivered.
Real projects, real results across industries where precision and reliability are non-negotiable
Mission-critical ruggedised electronics programme — zero failures across operational deployment.
Mission-critical ruggedised electronics programme — zero failures across operational deployment.
Problem
A defence system integrator needed IPC Class 3 PCB assemblies and wire harnesses for a ruggedised communications unit requiring conformal coating, vibration and thermal cycling validation, and complete component-level traceability for procurement audit.
Solution
We built dedicated assembly and harness lines with 100% AOI, X-ray on all BGAs, HiPot testing, automated conformal coating, and environmental stress screening with full documentation packages maintained throughout for procurement audit readiness.
Outcome
Zero failures across operational deployment. Procurement audit passed with complete traceability records. Programme extended with JINST for the next system variant.
0 operational failures · audit passed · programme extended
IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.
IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.
Problem
A consumer IoT brand needed to ramp from validated prototype to 20,000 retail-ready finished products - PCB assembly, enclosure integration, firmware loading, and retail packaging within a 10-week window to meet a retail launch commitment.
Solution
We managed the full programme - PCB assembly, box build, firmware loading, functional test, and retail packaging with parallel workstreams compressing the timeline and weekly progress updates keeping the client informed throughout.
Outcome
20,000 retail-ready units delivered within the 10-week window. Zero returns in the first 90 days post-launch. Client rated JINST 5/5 for quality and communication on the programme.
20,000 units · 10 weeks · zero 90-day returns
Rolling stock control electronics — zero in-service failures across 3-year deployment.
Rolling stock control electronics — zero in-service failures across 3-year deployment.
Problem
A rolling stock OEM needed ruggedised control PCB assemblies and wire harnesses for an auxiliary power unit requiring conformal coating, vibration testing, HiPot testing, and full traceability for safety certification documentation.
Solution
We built dedicated assembly and harness lines with automated conformal coating, vibration stress screening, 100% HiPot testing, and complete unit traceability with certification-supporting documentation delivered with every production batch.
Outcome
Zero in-service failures across 3-year deployment. Safety certification accepted with complete manufacturing records. We retained for spare parts supply across the platform lifecycle.
0 in-service failures · certification accepted · lifecycle support retained
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
Problem
A client was running an ageing through-hole PCB design with a 450-component BOM facing higher assembly costs, larger board size, component availability challenges, and reliability limitations inherent to a fully leaded design.
Solution
We redesigned the entire PCB converting 70% of components from PTH to SMD to create a hybrid design, replacing components where better modern equivalents existed, and optimising the layout for improved thermal performance and assembly efficiency.
Outcome
Hybrid PCB delivered with improved stability, reduced assembly cost, and a more manufacturable design achieving the client's cost-down objective without compromising product performance.
450-component BOM · 70% SMD conversion · cost reduction achieved
Read The Full Case Study
From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme
From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme
Problem
A PSU and private oil & gas client was dependent on imported wire harnesses for a 5000 HP gas engine system driving up costs and creating critical supply chain risk.
Solution
We reverse-engineered the harness, created full drawings and connection details, sourced domestic alternates to the same specification, and designed and manufactured 100+ harness variants entirely in-house.
Outcome
100+ harness variants developed and manufactured locally, reducing cost and eliminating supply dependency for a critical industrial system.
100+ harness variants · 5000 HP engine · full import substitution
Read The Full Case Study
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
Problem
A motor control PCB managing both AC and DC motors on an industrial machine was failing intermittently in the field with no clear pattern, and no confirmed root cause behind the fault.
Solution
Our engineering team reproduced the failure in lab conditions, identified an underrated component as the root cause, revised the component rating, updated the PCB layout, and validated the fix before rollout.
Outcome
A validated two-part engineering fix: a corrective action for machines already deployed, and a permanent circuit and layout change carried into new production closing the failure at its root, not just its symptom.
Root cause confirmed in lab · circuit redesigned · validated before rollout
Read The Full Case Study
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Problem
A medical device OEM required IPC Class 3 PCB assemblies for a diagnostic product with zero field failure tolerance, full component-level traceability for DHR, and ISO 13485-aligned documentation throughout the production run.
Solution
We configured a dedicated assembly line with 3D SPI, 100% AOI, X-ray on all BGA joints, ICT, and functional test with DHR-supporting traceability records maintained at component level throughout both production runs.
Outcome
Zero field failures across 50,000 units. Client passed ISO 13485 audit with complete traceability records. First pass yield maintained above 99.8% across both runs.
0 field failures · 99.8% FPY · ISO 13485 audit passed
Zero field failures across 50,000 medical PCB assemblies through multi-stage integrated testing.
Zero field failures across 50,000 medical PCB assemblies through multi-stage integrated testing.
Problem
A medical device OEM required IPC Class 3 PCB assemblies with zero tolerance for field failures and full unit-level traceability across a 50,000-unit production run with regulatory audit requirements.
Solution
We implemented a five-stage integrated test protocol - SPI pre-reflow, 100% AOI post-reflow, X-ray on all BGA joints, ICT, and functional test with unit-level traceability records maintained throughout.
Outcome
Outcome: Zero field failures across 50,000 units. Client passed regulatory audit with complete traceability records. First pass yield maintained above 99.8% across both production runs.
0 field failures · 99.8% FPY · full regulatory compliance
Reverse-engineered and redesigned full harness programme for a diesel generator system
Reverse-engineered and redesigned full harness programme for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Outcome: Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
End-to-end design and manufacture of a 15km-range drone communication box
End-to-end design and manufacture of a 15km-range drone communication box
Problem
A drone company needed a communication box capable of operating at up to 15km range covering radio control, telemetry, video, and payload protocols with no off-the-shelf solution available and no in-house electronics manufacturing capability to build it.
Solution
We designed and built the complete Base Com Box - hardware design, embedded software, drone communication protocol integration (ELRS, Crossfire, and others), and a fully tested, manufactured unit ready for mass production.
Outcome
A production-ready drone communication box with 15km operating range supporting RC, telemetry, video, and payload protocols designed, manufactured, tested, and scaled to mass production by us.
15km range · multi-protocol · design to mass production
EOL component crisis averted – 18 months before it would have stopped production.
EOL component crisis averted – 18 months before it would have stopped production.
Problem
A key microcontroller in a long-running industrial product was approaching end-of-life — with 18 months of production remaining and no qualified alternative in the BOM. The client wasn't aware until JINST flagged it.
Solution
We executed a last-time buy to cover the remaining production forecast, simultaneously qualifying an alternative component and validating it through a full DFM and functional test cycle.
Outcome
Production continuity maintained with zero interruption. Alternative component qualified and in production 6 months before last-time buy stock was exhausted.
Zero production interruption · 18-month EOL risk resolved
Avionics PCB assembly programme — zero failures through qualification testing and deployment.
Avionics PCB assembly programme — zero failures through qualification testing and deployment.
Problem
An avionics OEM needed IPC Class 3 PCB assemblies for a navigation module requiring fine-pitch BGA assembly, conformal coating, full component traceability, and thermal cycling validation to support certification submission.
Solution
We configured a dedicated line with 100% X-ray on all BGA joints, automated conformal coating, thermal cycling testing, and full chain-of-custody documentation with FAI reports and process validation records delivered with the first production batch.
Outcome
Zero failures through qualification testing. Certification documentation accepted first submission. Programme continued with JINST for subsequent platform variants.
0 qualification failures · certification accepted · programme extended
From brief to 15km range – designing and manufacturing a drone communication box end-to-end
From brief to 15km range – designing and manufacturing a drone communication box end-to-end
Problem
A drone company needed a communication box capable of operating at up to 15km range covering radio control, telemetry, video, and payload protocols with no off-the-shelf solution available and no in-house electronics manufacturing capability to build it.
Solution
We designed and built the complete Base Com Box - hardware design, embedded software, drone communication protocol integration (ELRS, Crossfire, and others), and a fully tested, manufactured unit ready for mass production.
Outcome
A production-ready drone communication box with 15km operating range supporting RC, telemetry, video, and payload protocols designed, manufactured, tested, and scaled to mass production by us.
15km range · multi-protocol · design to mass production
Read The Full Case Study
Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.
Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.
Problem
An industrial motor drive OEM was experiencing field failures on their previous supplier's assemblies traced to inadequate thermal interface material application and inconsistent HiPot testing. They needed a manufacturing partner with genuine power electronics discipline.
Solution
We conducted a DFM review identifying thermal and derating issues, implemented a dedicated assembly process with controlled TIM application, selective soldering, 100% HiPot testing, and burn-in at rated load before despatch.
Outcome
Zero field returns in first 12 months - versus 3.2% field failure rate with previous supplier. Client transferred full programme volume to us within 6 months of first delivery.
0% vs 3.2% field failure rate · full programme transferred
Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks
Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India. Solution
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
EOL component crisis averted — programme kept running 3 more years without redesign.
EOL component crisis averted — programme kept running 3 more years without redesign.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
5G base station PCB assembly — zero field failures across initial network deployment batch.
5G base station PCB assembly — zero field failures across initial network deployment batch.
Problem
A telecom OEM launching a new 5G base station module needed high-density BGA PCB assembly with signal integrity verification and functional testing on a compressed timeline to meet network operator deployment commitments.
Solution
We configured a dedicated line with 100% X-ray on all BGA joints, boundary scan testing, ICT, and full functional test completing NPI to production-ready in 8 weeks with test coverage designed for the specific signal paths of the board.
Outcome
Zero field failures across the initial deployment batch. Client met network operator deployment deadline. Programme scaled to full volume within 3 months of first production release.
0 field failures · 8-week NPI · on-time deployment
Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season
Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season
Problem
A solar inverter OEM needed weatherproof wire harness assemblies for outdoor residential installations - UV-rated materials, IP68 overmoulded connectors, and HiPot verification across a 5,000-unit initial production run.
Solution
We designed and built dedicated harness assemblies with UV-resistant PVC jacket, low-pressure overmoulded connectors to IP68, and 100% continuity and HiPot testing with environmental stress screening on a representative sample before production release.
Outcome
Zero field failures across the first installation season. IP68 rating verified on 100% of units. Client expanded programme to 15,000 units for the following year.
0 field failures · IP68 verified · 5,000 units delivered
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
Read The Full Case Study
Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season
Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season
Problem
A solar inverter OEM needed weatherproof wire harness assemblies for outdoor residential installations - UV-rated materials, IP68 overmoulded connectors, and HiPot verification across a 5,000-unit initial production run.
Solution
We designed and built dedicated harness assemblies with UV-resistant PVC jacket, low-pressure overmoulded connectors to IP68, and 100% continuity and HiPot testing with environmental stress screening on a representative sample before production release.
Outcome
Zero field failures across the first installation season. IP68 rating verified on 100% of units. Client expanded programme to 15,000 units for the following year.
0 field failures · IP68 verified · 5,000 units delivered
Rolling stock control electronics — zero in-service failures across 3-year deployment.
Rolling stock control electronics — zero in-service failures across 3-year deployment.
Problem
A rolling stock OEM needed ruggedised control PCB assemblies and wire harnesses for an auxiliary power unit requiring conformal coating, vibration testing, HiPot testing, and full traceability for safety certification documentation.
Solution
We built dedicated assembly and harness lines with automated conformal coating, vibration stress screening, 100% HiPot testing, and complete unit traceability with certification-supporting documentation delivered with every production batch.
Outcome
Zero in-service failures across 3-year deployment. Safety certification accepted with complete manufacturing records. We retained for spare parts supply across the platform lifecycle.
0 in-service failures · certification accepted · lifecycle support retained
5G base station PCB assembly — zero field failures across initial network deployment batch.
5G base station PCB assembly — zero field failures across initial network deployment batch.
Problem
A telecom OEM launching a new 5G base station module needed high-density BGA PCB assembly with signal integrity verification and functional testing on a compressed timeline to meet network operator deployment commitments.
Solution
We configured a dedicated line with 100% X-ray on all BGA joints, boundary scan testing, ICT, and full functional test completing NPI to production-ready in 8 weeks with test coverage designed for the specific signal paths of the board.
Outcome
Zero field failures across the initial deployment batch. Client met network operator deployment deadline. Programme scaled to full volume within 3 months of first production release.
0 field failures · 8-week NPI · on-time deployment
From brief to 15km range – designing and manufacturing a drone communication box end-to-end
From brief to 15km range – designing and manufacturing a drone communication box end-to-end
Problem
A drone company needed a communication box capable of operating at up to 15km range covering radio control, telemetry, video, and payload protocols with no off-the-shelf solution available and no in-house electronics manufacturing capability to build it.
Solution
We designed and built the complete Base Com Box - hardware design, embedded software, drone communication protocol integration (ELRS, Crossfire, and others), and a fully tested, manufactured unit ready for mass production.
Outcome
A production-ready drone communication box with 15km operating range supporting RC, telemetry, video, and payload protocols designed, manufactured, tested, and scaled to mass production by us.
15km range · multi-protocol · design to mass production
Read The Full Case Study
Mission-critical ruggedised electronics programme — zero failures across operational deployment.
Mission-critical ruggedised electronics programme — zero failures across operational deployment.
Problem
A defence system integrator needed IPC Class 3 PCB assemblies and wire harnesses for a ruggedised communications unit requiring conformal coating, vibration and thermal cycling validation, and complete component-level traceability for procurement audit.
Solution
We built dedicated assembly and harness lines with 100% AOI, X-ray on all BGAs, HiPot testing, automated conformal coating, and environmental stress screening with full documentation packages maintained throughout for procurement audit readiness.
Outcome
Zero failures across operational deployment. Procurement audit passed with complete traceability records. Programme extended with JINST for the next system variant.
0 operational failures · audit passed · programme extended
IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.
IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.
Problem
A consumer IoT brand needed to ramp from validated prototype to 20,000 retail-ready finished products - PCB assembly, enclosure integration, firmware loading, and retail packaging within a 10-week window to meet a retail launch commitment.
Solution
We managed the full programme - PCB assembly, box build, firmware loading, functional test, and retail packaging with parallel workstreams compressing the timeline and weekly progress updates keeping the client informed throughout.
Outcome
20,000 retail-ready units delivered within the 10-week window. Zero returns in the first 90 days post-launch. Client rated JINST 5/5 for quality and communication on the programme.
20,000 units · 10 weeks · zero 90-day returns
Rolling stock control electronics — zero in-service failures across 3-year deployment.
Rolling stock control electronics — zero in-service failures across 3-year deployment.
Problem
A rolling stock OEM needed ruggedised control PCB assemblies and wire harnesses for an auxiliary power unit requiring conformal coating, vibration testing, HiPot testing, and full traceability for safety certification documentation.
Solution
We built dedicated assembly and harness lines with automated conformal coating, vibration stress screening, 100% HiPot testing, and complete unit traceability with certification-supporting documentation delivered with every production batch.
Outcome
Zero in-service failures across 3-year deployment. Safety certification accepted with complete manufacturing records. We retained for spare parts supply across the platform lifecycle.
0 in-service failures · certification accepted · lifecycle support retained
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
Problem
A client was running an ageing through-hole PCB design with a 450-component BOM facing higher assembly costs, larger board size, component availability challenges, and reliability limitations inherent to a fully leaded design.
Solution
We redesigned the entire PCB converting 70% of components from PTH to SMD to create a hybrid design, replacing components where better modern equivalents existed, and optimising the layout for improved thermal performance and assembly efficiency.
Outcome
Hybrid PCB delivered with improved stability, reduced assembly cost, and a more manufacturable design achieving the client's cost-down objective without compromising product performance.
450-component BOM · 70% SMD conversion · cost reduction achieved
Read The Full Case Study
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
Problem
A motor control PCB managing both AC and DC motors on an industrial machine was failing intermittently in the field with no clear pattern, and no confirmed root cause behind the fault.
Solution
Our engineering team reproduced the failure in lab conditions, identified an underrated component as the root cause, revised the component rating, updated the PCB layout, and validated the fix before rollout.
Outcome
A validated two-part engineering fix: a corrective action for machines already deployed, and a permanent circuit and layout change carried into new production closing the failure at its root, not just its symptom.
Root cause confirmed in lab · circuit redesigned · validated before rollout
Read The Full Case Study
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Problem
A medical device OEM required IPC Class 3 PCB assemblies for a diagnostic product with zero field failure tolerance, full component-level traceability for DHR, and ISO 13485-aligned documentation throughout the production run.
Solution
We configured a dedicated assembly line with 3D SPI, 100% AOI, X-ray on all BGA joints, ICT, and functional test with DHR-supporting traceability records maintained at component level throughout both production runs.
Outcome
Zero field failures across 50,000 units. Client passed ISO 13485 audit with complete traceability records. First pass yield maintained above 99.8% across both runs.
0 field failures · 99.8% FPY · ISO 13485 audit passed
Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.
Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.
Problem
An industrial motor drive OEM was experiencing field failures on their previous supplier's assemblies traced to inadequate thermal interface material application and inconsistent HiPot testing. They needed a manufacturing partner with genuine power electronics discipline.
Solution
We conducted a DFM review identifying thermal and derating issues, implemented a dedicated assembly process with controlled TIM application, selective soldering, 100% HiPot testing, and burn-in at rated load before despatch.
Outcome
Zero field returns in first 12 months - versus 3.2% field failure rate with previous supplier. Client transferred full programme volume to us within 6 months of first delivery.
0% vs 3.2% field failure rate · full programme transferred
Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks
Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India. Solution
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
5G base station PCB assembly — zero field failures across initial network deployment batch.
5G base station PCB assembly — zero field failures across initial network deployment batch.
Problem
A telecom OEM launching a new 5G base station module needed high-density BGA PCB assembly with signal integrity verification and functional testing on a compressed timeline to meet network operator deployment commitments.
Solution
We configured a dedicated line with 100% X-ray on all BGA joints, boundary scan testing, ICT, and full functional test completing NPI to production-ready in 8 weeks with test coverage designed for the specific signal paths of the board.
Outcome
Zero field failures across the initial deployment batch. Client met network operator deployment deadline. Programme scaled to full volume within 3 months of first production release.
0 field failures · 8-week NPI · on-time deployment
Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season
Solar inverter wire harness programme – IP68 verified, zero field failures across first deployment season
Problem
A solar inverter OEM needed weatherproof wire harness assemblies for outdoor residential installations - UV-rated materials, IP68 overmoulded connectors, and HiPot verification across a 5,000-unit initial production run.
Solution
We designed and built dedicated harness assemblies with UV-resistant PVC jacket, low-pressure overmoulded connectors to IP68, and 100% continuity and HiPot testing with environmental stress screening on a representative sample before production release.
Outcome
Zero field failures across the first installation season. IP68 rating verified on 100% of units. Client expanded programme to 15,000 units for the following year.
0 field failures · IP68 verified · 5,000 units delivered
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
Read The Full Case Study
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
Problem
A client was running an ageing through-hole PCB design with a 450-component BOM facing higher assembly costs, larger board size, component availability challenges, and reliability limitations inherent to a fully leaded design.
Solution
We redesigned the entire PCB converting 70% of components from PTH to SMD to create a hybrid design, replacing components where better modern equivalents existed, and optimising the layout for improved thermal performance and assembly efficiency.
Outcome
Hybrid PCB delivered with improved stability, reduced assembly cost, and a more manufacturable design achieving the client's cost-down objective without compromising product performance.
450-component BOM · 70% SMD conversion · cost reduction achieved
Read The Full Case Study
From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme
From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme
Problem
A PSU and private oil & gas client was dependent on imported wire harnesses for a 5000 HP gas engine system driving up costs and creating critical supply chain risk.
Solution
We reverse-engineered the harness, created full drawings and connection details, sourced domestic alternates to the same specification, and designed and manufactured 100+ harness variants entirely in-house.
Outcome
100+ harness variants developed and manufactured locally, reducing cost and eliminating supply dependency for a critical industrial system.
100+ harness variants · 5000 HP engine · full import substitution
Read The Full Case Study
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
Problem
A motor control PCB managing both AC and DC motors on an industrial machine was failing intermittently in the field with no clear pattern, and no confirmed root cause behind the fault.
Solution
Our engineering team reproduced the failure in lab conditions, identified an underrated component as the root cause, revised the component rating, updated the PCB layout, and validated the fix before rollout.
Outcome
A validated two-part engineering fix: a corrective action for machines already deployed, and a permanent circuit and layout change carried into new production closing the failure at its root, not just its symptom.
Root cause confirmed in lab · circuit redesigned · validated before rollout
Read The Full Case Study
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Problem
A medical device OEM required IPC Class 3 PCB assemblies for a diagnostic product with zero field failure tolerance, full component-level traceability for DHR, and ISO 13485-aligned documentation throughout the production run.
Solution
We configured a dedicated assembly line with 3D SPI, 100% AOI, X-ray on all BGA joints, ICT, and functional test with DHR-supporting traceability records maintained at component level throughout both production runs.
Outcome
Zero field failures across 50,000 units. Client passed ISO 13485 audit with complete traceability records. First pass yield maintained above 99.8% across both runs.
0 field failures · 99.8% FPY · ISO 13485 audit passed
EOL component crisis averted – 18 months before it would have stopped production.
EOL component crisis averted – 18 months before it would have stopped production.
Problem
A key microcontroller in a long-running industrial product was approaching end-of-life — with 18 months of production remaining and no qualified alternative in the BOM. The client wasn't aware until JINST flagged it.
Solution
We executed a last-time buy to cover the remaining production forecast, simultaneously qualifying an alternative component and validating it through a full DFM and functional test cycle.
Outcome
Production continuity maintained with zero interruption. Alternative component qualified and in production 6 months before last-time buy stock was exhausted.
Zero production interruption · 18-month EOL risk resolved
From brief to 15km range – designing and manufacturing a drone communication box end-to-end
From brief to 15km range – designing and manufacturing a drone communication box end-to-end
Problem
A drone company needed a communication box capable of operating at up to 15km range covering radio control, telemetry, video, and payload protocols with no off-the-shelf solution available and no in-house electronics manufacturing capability to build it.
Solution
We designed and built the complete Base Com Box - hardware design, embedded software, drone communication protocol integration (ELRS, Crossfire, and others), and a fully tested, manufactured unit ready for mass production.
Outcome
A production-ready drone communication box with 15km operating range supporting RC, telemetry, video, and payload protocols designed, manufactured, tested, and scaled to mass production by us.
15km range · multi-protocol · design to mass production
Read The Full Case Study
EOL component crisis averted — programme kept running 3 more years without redesign.
EOL component crisis averted — programme kept running 3 more years without redesign.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
Read The Full Case Study
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
Problem
A motor control PCB managing both AC and DC motors on an industrial machine was failing intermittently in the field with no clear pattern, and no confirmed root cause behind the fault.
Solution
Our engineering team reproduced the failure in lab conditions, identified an underrated component as the root cause, revised the component rating, updated the PCB layout, and validated the fix before rollout.
Outcome
A validated two-part engineering fix: a corrective action for machines already deployed, and a permanent circuit and layout change carried into new production closing the failure at its root, not just its symptom.
Root cause confirmed in lab · circuit redesigned · validated before rollout
Read The Full Case Study
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
Read The Full Case Study
EOL component crisis averted – 18 months before it would have stopped production.
EOL component crisis averted – 18 months before it would have stopped production.
Problem
A key microcontroller in a long-running industrial product was approaching end-of-life — with 18 months of production remaining and no qualified alternative in the BOM. The client wasn't aware until JINST flagged it.
Solution
We executed a last-time buy to cover the remaining production forecast, simultaneously qualifying an alternative component and validating it through a full DFM and functional test cycle.
Outcome
Production continuity maintained with zero interruption. Alternative component qualified and in production 6 months before last-time buy stock was exhausted.
Zero production interruption · 18-month EOL risk resolved
EOL component crisis averted — programme kept running 3 more years without redesign.
EOL component crisis averted — programme kept running 3 more years without redesign.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme
From import dependency to indigenous manufacturing — 100+ harness variants developed for a 5000 HP gas engine programme
Problem
A PSU and private oil & gas client was dependent on imported wire harnesses for a 5000 HP gas engine system driving up costs and creating critical supply chain risk.
Solution
We reverse-engineered the harness, created full drawings and connection details, sourced domestic alternates to the same specification, and designed and manufactured 100+ harness variants entirely in-house.
Outcome
100+ harness variants developed and manufactured locally, reducing cost and eliminating supply dependency for a critical industrial system.
100+ harness variants · 5000 HP engine · full import substitution
Read The Full Case Study
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
Problem
A client was running an ageing through-hole PCB design with a 450-component BOM facing higher assembly costs, larger board size, component availability challenges, and reliability limitations inherent to a fully leaded design.
Solution
We redesigned the entire PCB converting 70% of components from PTH to SMD to create a hybrid design, replacing components where better modern equivalents existed, and optimising the layout for improved thermal performance and assembly efficiency.
Outcome
Hybrid PCB delivered with improved stability, reduced assembly cost, and a more manufacturable design achieving the client's cost-down objective without compromising product performance.
450-component BOM · 70% SMD conversion · cost reduction achieved
Read The Full Case Study
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Problem
A medical device OEM required IPC Class 3 PCB assemblies for a diagnostic product with zero field failure tolerance, full component-level traceability for DHR, and ISO 13485-aligned documentation throughout the production run.
Solution
We configured a dedicated assembly line with 3D SPI, 100% AOI, X-ray on all BGA joints, ICT, and functional test with DHR-supporting traceability records maintained at component level throughout both production runs.
Outcome
Zero field failures across 50,000 units. Client passed ISO 13485 audit with complete traceability records. First pass yield maintained above 99.8% across both runs.
0 field failures · 99.8% FPY · ISO 13485 audit passed
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
PTH to hybrid SMD redesign – 450-component BOM converted to 70% SMD for better stability and lower cost.
Problem
A client was running an ageing through-hole PCB design with a 450-component BOM facing higher assembly costs, larger board size, component availability challenges, and reliability limitations inherent to a fully leaded design.
Solution
We redesigned the entire PCB converting 70% of components from PTH to SMD to create a hybrid design, replacing components where better modern equivalents existed, and optimising the layout for improved thermal performance and assembly efficiency.
Outcome
Hybrid PCB delivered with improved stability, reduced assembly cost, and a more manufacturable design achieving the client's cost-down objective without compromising product performance.
450-component BOM · 70% SMD conversion · cost reduction achieved
Read The Full Case Study
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
From recurring field failure to permanent fix: debugging a motor control PCB under pressure
Problem
A motor control PCB managing both AC and DC motors on an industrial machine was failing intermittently in the field with no clear pattern, and no confirmed root cause behind the fault.
Solution
Our engineering team reproduced the failure in lab conditions, identified an underrated component as the root cause, revised the component rating, updated the PCB layout, and validated the fix before rollout.
Outcome
A validated two-part engineering fix: a corrective action for machines already deployed, and a permanent circuit and layout change carried into new production closing the failure at its root, not just its symptom.
Root cause confirmed in lab · circuit redesigned · validated before rollout
Read The Full Case Study
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Reverse engineering to mass production — complete harness redesign for a diesel generator system
Problem
A diesel generator manufacturer needed their existing harness system redesigned and fully documented with no original drawings available, undefined current requirements, and a need to support both customisation and mass production going forward.
Solution
We reverse-engineered the system, defined all connection and current requirements, selected wire parameters, analysed sensor outputs and voltage drop across every sensing link, then designed full connection routing, bunching, electrical diagrams, and manufacturing drawings.
Outcome
Complete harness programme delivered from system understanding and parameter definition through to electrical diagrams, manufacturing drawings, sample production, and full mass production support.
Full system redesign · end-to-end documentation · prototype to mass production
Read The Full Case Study
IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.
IoT consumer product – 20,000 retail-ready units delivered in 10 weeks with zero 90-day returns.
Problem
A consumer IoT brand needed to ramp from validated prototype to 20,000 retail-ready finished products - PCB assembly, enclosure integration, firmware loading, and retail packaging within a 10-week window to meet a retail launch commitment.
Solution
We managed the full programme - PCB assembly, box build, firmware loading, functional test, and retail packaging with parallel workstreams compressing the timeline and weekly progress updates keeping the client informed throughout.
Outcome
20,000 retail-ready units delivered within the 10-week window. Zero returns in the first 90 days post-launch. Client rated JINST 5/5 for quality and communication on the programme.
20,000 units · 10 weeks · zero 90-day returns
Mission-critical ruggedised electronics programme — zero failures across operational deployment.
Mission-critical ruggedised electronics programme — zero failures across operational deployment.
Problem
A defence system integrator needed IPC Class 3 PCB assemblies and wire harnesses for a ruggedised communications unit requiring conformal coating, vibration and thermal cycling validation, and complete component-level traceability for procurement audit.
Solution
We built dedicated assembly and harness lines with 100% AOI, X-ray on all BGAs, HiPot testing, automated conformal coating, and environmental stress screening with full documentation packages maintained throughout for procurement audit readiness.
Outcome
Zero failures across operational deployment. Procurement audit passed with complete traceability records. Programme extended with JINST for the next system variant.
0 operational failures · audit passed · programme extended
Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks
Industrial IoT gateway from prototype to 5,000 deployed units in 12 weeks
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India. Solution
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.
Industrial motor drive PCB programme – thermal validated, HiPot cleared, zero field returns.
Problem
An industrial motor drive OEM was experiencing field failures on their previous supplier's assemblies traced to inadequate thermal interface material application and inconsistent HiPot testing. They needed a manufacturing partner with genuine power electronics discipline.
Solution
We conducted a DFM review identifying thermal and derating issues, implemented a dedicated assembly process with controlled TIM application, selective soldering, 100% HiPot testing, and burn-in at rated load before despatch.
Outcome
Zero field returns in first 12 months - versus 3.2% field failure rate with previous supplier. Client transferred full programme volume to us within 6 months of first delivery.
0% vs 3.2% field failure rate · full programme transferred
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Zero-defect wire harness delivery across a 50,000-unit automotive programme.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Zero field failures across a 50,000-unit medical PCB programme with full regulatory audit compliance.
Problem
A medical device OEM required IPC Class 3 PCB assemblies for a diagnostic product with zero field failure tolerance, full component-level traceability for DHR, and ISO 13485-aligned documentation throughout the production run.
Solution
We configured a dedicated assembly line with 3D SPI, 100% AOI, X-ray on all BGA joints, ICT, and functional test with DHR-supporting traceability records maintained at component level throughout both production runs.
Outcome
Zero field failures across 50,000 units. Client passed ISO 13485 audit with complete traceability records. First pass yield maintained above 99.8% across both runs.
0 field failures · 99.8% FPY · ISO 13485 audit passed
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Zero field failures across 50,000 units — ISO 13485 audit passed with full traceability.
Problem
An IIoT startup needed to move from validated prototype to 5,000 deployed industrial gateways requiring PCB assembly, IP67 enclosure integration, firmware loading, LoRa module testing, and direct despatch to customer sites across India.
Solution
We managed the full programme - PCB assembly with RF module integration, IP67 box build, firmware flashing and functional test, and direct despatch to customer sites with parallel workstreams compressing the 12-week timeline.
Outcome
5,000 units deployed within 12 weeks. Zero connectivity failures reported post-deployment. Client scaled programme to 20,000 units for the following quarter.
5,000 units · 12 weeks · zero connectivity failures
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