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    CASE STUDY - INTELLIGENT LIGHTING
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    Delivering consistency and flexibility for a global leader in lighting control systems

    A global pioneer in smart lighting solutions has trusted ESCATEC as a manufacturing partner since 2010. During the past 15 years, ESCATEC has supported the company with a broad and diverse product portfolio, currently managing close to 100 active variants across more than a dozen different product families.

     

    Renowned for its innovation and high-quality lighting control systems, the customer depends on ESCATEC’s flexibility, technical expertise, and vertically integrated capabilities to consistently deliver against varying demand patterns.

     

    The company required a partner capable of handling high-mix, low-volume production, combining PCBA, box-build assembly, and plastic injection moulding under one roof.
    The Challenge

    As a long-term partner, ESCATEC has continuously adapted to the customer’s evolving needs and product complexity:

    • High-mix, low-volume production: Demand is spread across multiple product variants and significantly different volumes (ranging from just 2 units to 2000 units per month), requiring careful product scheduling, robust supply chain management, and flexible manufacturing capacity.

    • Frequent design and component changes: Regular product updates (hardware and software), Engineering Change Notes, and component end-of-life challenges demand fast responses and close communication between engineering and procurement teams.

    • Capacity and manpower: Managing fluctuating demand while retaining experienced operators and training new staff poses an ongoing challenge.

    • Technical precision in plastic components: Tight tolerances and resin variations in injection moulding require continuous fine-tuning and testing to meet exacting standards.

    • Knowledge-intensive assembly: The assembly process relies on skilled operators, many with over five years’ experience, ensuring consistent quality that would be difficult to replicate.

    The Solution

    ESCATEC’s team works closely with the customer’s engineering and procurement teams to maintain seamless communication and efficient problem-solving.

    • Integrated in-house manufacturing: By combining PCBA, box-build, and plastic injection moulding under one roof, ESCATEC eliminates the need for multiple suppliers, improving coordination and reducing lead times.

    • Adaptable production lines to meet changing demand: The team continuously optimises assembly lines to handle an increasingly diverse product range and variable monthly quantities.

    • Experienced workforce: Skilled operators and dedicated training ensure consistent assembly quality, even across a wide range of product variants.

    • Strong process control: Established failure analysis guidelines and process documentation enable operators to address potential issues promptly, without production delays.

    The Results

    • Long-term growth: approx. 20 % CAGR over 15 years, powered by ESCATEC’s integrated manufacturing and agile support.

    • High-quality output: Consistent deliveries across nearly 100 product variants and multiple product families.

    • Comprehensive in-house services: From electronics to plastics, ESCATEC provides a wide range of vertically integrated services under one roof. This eliminates the need for the customer to manage multiple external suppliers, increases overall flexibility, and helps keep overhead costs low.

    • Future scalability: With new project transfers already planned and the potential for automation projects in the future, ESCATEC is well-positioned to support the on-going growth goals of the customer, allowing them to further increase market share within the lighting controls sector.