We provide New Product Introduction Services to get you from the design concept to the production line. The best solutions start with early manufacturing knowledge incorporated into the very early concept stage of design where it matters most. Did you know 70% of a product cost is locked in during this early stage?
Our Commercialization Expert helps you to:
Find Off the Shelf Components – it is important to find choices from Global Suppliers.
The Design Team starts with the right information early which saves development, prototyping and testing costs.
Mechanical item sourcing includes off the shelf (OTS) and custom modified off the shelf (COTS) plastic, metal, rubber, composite… parts that get made through many processes including molding, machining, forming, casting, rapid prototyping. Finding the right component for function and cost can be very challenging. Knowing where to look and who to ask is very important.
Electrical/ Electronic item sourcing - includes PCBA. Device-component sourcing, PCB builds, test protocol
Create High level Key Item Cost Estimates – early initial estimates of major parts and components.
Getting the important design part and custom tooling cost targets planned helps the business planning for unit cost and pricing. Cost estimating is essential for the design team to make appropriate decisions as well.
Part Supply Logistic Planning – as early as possible determine where the product will be manufactured.
North America - Asia - Mexico). What volumes are expected and what materials will be used will help with the early stage design, manufacture and business planning.
Find the best fit Contract Manufacturer – to build your product in volumes from 100’s to 100,000’s of units.
Create the Product File – contains hundreds of pages of documentation necessary to define a product.
The cornerstone of a successful product in production is the accurate creation and maintenance of the Product File. The product file contains all the details that each manufacturer of interest must comply with in order to build your product. As the product file evolves it will contain the properly captured up to date details to send accurate information to potential future suppliers and manufacturers. Our clients can help out by finding and opening discussions with as many potential suppliers and manufacturers as they feel are necessary to ensure low risk production. Our role is to ensure all supplier discussions have the correct information at any given time. Our clients rely on us to act as technical experts in supplier discussion to facilitate clear information transfer increasing benefiting relationships and good decision making.
The Product File Includes – a variety of information for part ordering and final assembly Manufacturer builds.
- ➢ 3D CAD of all parts and assemblies in parametric format for low cost update and maintenance
- ➢ 2D CAD documentation of parts, assemblies and specification information for manufacture
- ➢ Product items structure –Bill of Material - BOM Structure - Top Level Indented BOM structure
- ➢ P/N / revision structure ➢ SCD’s- Specification Control Documents
- ➢ Supplier selection - Approved vendor List (AVL)
- ➢ Manufacturing build process flow and procedures
- ➢ Testing- Function test and System test-Jigs and fixtures
- ➢ Product Assembly Documents
- ➢ Quality Control Documents
- ➢ QMS –Documents
- ➢ Quality metrics - define inputs and outputs by Recording and Analyzing data
- ➢ Process and procedure definition - system for corporate governance
- ➢ Purchase order, Sales orders, Invoicing processes
- ➢ Approved Vendor list- AVL
- ➢ Quality management system- QMS
- ➢ Quality Control System
Establish the Development Schedule – creation and update with realistic times for all phases. We work with you to keep the physical design-development program on schedule to enable building high quality product.
Product Quality Control Plan – We help you put methods in place to monitor the quality by helping you define defects, set quality assurance levels and monitor with auditing procedures. We create content and documentation for the Unit Packaging, Shipping and Product labels, graphics and drawings.
Shipping and Logistics Details
Frequently Asked Questions - about Off-Shore Manufacturing
Who are we actually buying any custom tooling from, is it the company that is actually building it?
We work with our interface in Asia, they make sure the each custom part tooler delivers a tool that will molds each part correctly.
What obligations do we have to the tooler and the interface company overseas?
At any time you can take away the tool by presenting the letter to the tooler or requesting the Asian interface to request the tool to be shipped to a third party. However, the letter gives you only the right to take back the tool but not the right to place order directly to this same tooler unless the Asian interface agrees or no longer exists. Vice versa, the tooler will not accept direct order from you as they have relationship with the interface company. All business activities needs to go thru the Asian Interface for the duration of product life as this is how they make back their investment in setting up and managing the relationship for you.
What exactly is the Asian Interface role?
The Asian Interface is your representative in front of manufacturers providing the support in operational and technical matters during development and during production. They are also the person the manufacturers trust and gives the manufacturers trust that you are credible and that the interface person will be responsible to the order placed and make sure the manufacturers will get paid. One of the most important roles the interface does for you is to transfer information correctly to save you trips to Asia, order mistakes and the multitude of correspondence details the manufacturer requires to fulfill your order.
Do you deal direct with any manufacturing plants yourself?
YES – relationships take time, to reduce cost and errors it is best to deal with the people you know and trust and have someone that knows each factory well that can support you (time difference language ETC.). Not all errors get caught but a far greater effectiveness is arrived at quickly especially for people new to the process.
What happens if the overseas coordination company disappears, how and where do we pick up our tool? We need to know exactly who is in possession of our tool.
The tooler is selected by your interface in Asia with our help when the tooling paperwork is signed. A contact for the tooler and their company is provided. Our interface person makes sure the communications during tool build does not suffer from language transfer. Once tools are built and paid for you own the tools. They can be transported at your cost anywhere you require after the contract obligations are met (such as discounts based on minimum part production which is one option in agreement). As an extra measure we send an ownership declaration letter to the Tooler saying the tools belong to your company. We then have the tooler send an email showing their acknowledgement of the ownership of tool.
Is it risky using a company across the globe to manufacture for me?
There are many companies with high integrity in many countries. We choose to work with the companies that have a good track record and have built up a library of companies that make a wide variety of high quality custom parts. Each company is expert in one or more types of parts. Your product may have hundreds of parts and dozens of custom parts. Finding a final assembly manufacturer is important and they will deal with the quality of the many parts and be responsible for the delivery of the overall product. Sourcing companies at a distance with no help that can visit and monitor the factory is very risky and almost all the time ends with problems. Our team will help ensure you don’t experience this problem as it is costly and wastes a year of your time to sort out the mess. Everything goes well until there are quality and defect problems and you are left holding the bill. If you plan your supply strategy effectively you will minimize your costs and issues of preparing for production and ongoing customer service.