CASE STUDY:
The power management systems had a transformer soldered to the PCB that was showing to be too weak in some situations when prolonged max loads were applied. As a result, there were failures in the field. Their engineers identified that a transformer on the PCB board needed upgrading. During this upgrade, a resistor and a capacitor also required replacing.
During the process, old components required desoldering, and the connection points on the PCB board were cleaned. Afterward, new components were resoldered to the PCB board. Once new components were resoldered, software updates and power tests were performed to ensure the new components were affixed to the board correctly and could perform under max loads.
Before new components were soldered to the PCB board, they were to tested to ensure they were within stated manufacture tolerances and that there wouldn’t be a repeat of the same issue again.
Each completed unit needed serial numbers recorded, repackaged into new packing, and updated labeling applied to the box. This process was estimated to take 90 minutes per unit, and 650 units needed reworking.
The time commitment to the rework was a massive undertaking. Turnaround time needed to be within 60 days, and on top of that, a skilled workforce was required.
Each that failed was a direct revenue loss of more than $2000 with more than 1,300,000 on the line.
Supply Source Options leveraged its competitive advantages with its creative problem-solving leadership, proprietary inventory software systems, and skilled/seasoned workforce.
Work instructions were presented and rehearsed with all technicians working on the rework. Advanced electronic testing and soldering tools were purchased and trained with.
The first unit took more than 8 hours to complete. The second and third units were completed in under 4 hours.
Then after six units, all teams hit their strides of 90 minutes per unit, and the initial test units were reworked without failures.
Access to our proprietary inventory software systems allows the manufacturer to see the exact inventory model numbers reworked at the end of each day.
And because of our “all-in pricing” model, which included specialized tools purchased, training, warehousing, and the reworking label, their costs are simple and always predictable!
All 650 units were reworked in less than 60 days. A failure rate of 5% was budgeted and expected during the rework process.
S2O kept this rate under 2.4%, far below engineering expectations. The units have seen more than a year of infield action, and no additional failures in the field have occurred, as previously found.
The marine manufacturer’s Sales VP was “ecstatic by S2O’s performance.” He couldn’t believe that S2O could add more than 1 million to topline revenue that was thought to be lost. S2O is being considered for additional assembly and rework projects.
Because of the efficiencies gained from outsourcing a challenging rework project, the manufacturer can focus on what they do well with their current labor constraints, producing products, focusing on product innovation, and leaving various assembly and rework projects for S2O.
TES America