SOLUTION

INNOVATE

At ESCATEC, we help our customers Innovate, Scale, and Repeat. We make the transition between design and manufacturing seamless. And we work with you to extend the lifetime of products out in the marketplace whilst supporting you with the next iteration. It’s a continuous cycle of improvement.

You are an inventor. You have the idea, the concept, the vision of what you want to create. So, together, we Innovate. Through our design and development and NPI processes, we take your idea and make it a reality by turning it into a market leading product.


Product Design & Development

Electronics, Software, Mechanical and System Design.

A successful product requires a well thought-out design. We take your idea and transform it into a fully certified product, ready to manufacture at the lowest cost of ownership.

You’re not the first OEM to feel frustrated by the lack of time left to focus on innovation and growth. Growth = profit. We understand that more than anyone. But growth only comes when operations run efficiently; when they’re underpinned by focused teams and strategies, and when you’re armed with a complete design and manufacturing solution.

What is your greatest challenge? Are you struggling to recruit the right staff? Are you unable to react quickly to client demands? Or perhaps you’re losing precious engineering and design time?

Product-Design-and-Development

Whatever your challenges, ESCATEC has the internal management, design and production capabilities to assist you throughout the entire product lifecycle from introduction through to decline and obsolescence management – all while ensuring consistent and long-term business growth.

Working closely with you, our engineers help define the architecture of your product to satisfy your specific requirements.

What sets ESCATEC apart from a traditional design house is the strong focus we apply to design for manufacturability during the product development phase. This approach eliminates waste, reduces cost and helps ensure your products are delivered to market in the shortest possible time.

Since 1974, our customers have trusted us to deliver the designs they vision.

Whether you require support with electronics hardware, software or mechanical design, we have the in-house experience you need to deliver the highest quality products and service.

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Design for eXcellence

80% of cost is typically determined during product design. That’s why we begin early with DfX, encompassing all design and manufacturing processes. Your product is continuously optimised for performance and quality, improving time-to-market and your complete satisfaction.

DfX ensures:

  • Specified materials and components will always be available/replaceable
  • Manufacturing waste is minimised
  • Production errors are minimised
  • Products always meet required standards
  • Products can be tested easily and cost-effectively
DESIGN FOR PROCUREMENT

The success of any new product relies on effective selection of all components, materials, and suppliers. ESCATEC has Design for Procurement (DfP) expertise across electrical, electronic, mechanical, and electro-mechanical disciplines. And with highly experienced purchasing and engineering groups within Malaysia, Switzerland, Czech Republic, and the UK with access to a global network of suppliers, we are ideally placed to advise and support customers at the critical design stage.

Getting this right will have an important impact on the products viability throughout its lifecycle and provide significant benefits downstream, including:

  • Reduced time-to-market
  • Lower material lead-time
  • Minimised material liability
  • Consolidated suppliers
  • Extended product lifecycle
DESIGN FOR MANUFACTURE

Design for Manufacture (DFM), sometimes called Design for Manufacturability, is the element of the design effort that focusses on producibility to enable the product to be assembled in the most cost-effective manner, in a shorter time frame, with superior quality.

As most of the product lifecycle costs are committed at design stage, this is clearly a critical stage in the overall product design process. The concept of design for manufacture may be found across most engineering disciplines, but the specific details will clearly vary according to the manufacturing technologies being harnessed. Getting this right will have an important impact on the product’s viability throughout its lifecycle.

ESCATEC has considerable experience in working with customers at this critical stage to help to ensure that their designs are optimised for the manufacturing processes that will be used downstream and that all factors such as component specifications, dimensional tolerances and the required secondary processes are all considered.

This approach is applied equally to all manufacturing projects that ESCATEC undertake, i.e., PCB assemblies, box build assemblies, cable harnesses and looms, panel wiring, system integration and electro-mechanical builds.

Design for Manufacture has the potential to generate significant improvements, such as:

  • Enhanced manufacturing productivity
  • Improved product quality and reliability
  • Reduced/simplified maintenance
  • Reduced cost
  • Decreased time to market
  • Increased customer satisfaction
DESIGN FOR TEST (DFT)

Design for Test (DFT) sometimes called Design for Testability is the element of the design effort that focusses on ensuring that the required level of testability features are incorporated into hardware product designs in order to make it easier to develop and apply manufacturing tests.

This is a critical process as PCB assemblies have become increasingly more complex and the ability to test these using traditional methods and systems has become more difficult. Therefore considering design for test in the early stages of product development is vitally important in order to ensure that adequate fault coverage and diagnostic ability is available. 

DFT delivers benefits including:

  • Increased test coverage
  • Reduced test times
  • Simpler test requirements
DESIGN FOR QUALITY

A Design for Quality (DfQ) strategy identifies potential product and process failure risks as early as possible to ensure they are ‘designed out’ of the product.  

A DfQ approach can prevent you from getting locked into compliant but not necessarily cost-effective designs.  If a design has proceeded to the prototype stage and been validated for regulatory compliance, you may be committed to manufacturing a product in a certain way for a lengthy period. It might not make sense to re-submit your design to regulators at that point - so your ROI and customer value could be severely impacted.  

At ESCATEC we take a holistic approach to DfQ so that the best value and quality outcomes for customers are always achieved.

DfQ ensures quality by:

  • Identifying potential quality risks through Design Failure Mode and Effects Analysis (DFMEA), ranking potential severity of failures and prioritising areas for action.
  • Ensuring products are designed so they can only be assembled one specific way, minimising potential non-conformities.
  • Simplifying the design to reduce costs and the risk of failure.
  • Standardising parts where possible so compliance is easier to establish.
  • Having a multi-functional team of experts to drive the process ensures the overall quality of the product is maintained within the design.
  • Ensuring required documentation is completed within the design process helps prove regulatory compliance - helping you achieve ISO 13485, ISO 9001, CE marking and FDA certification as required.  
  • Ensuring design processes are stage-gated to continually validate deliverables against engineering/customer/regulatory requirements. Stage gating your design process is a requirement of the medical device development standard ISO 13485:2016.
  • Ensuring required manufacturing processes are documented, validated, and engineers are appropriately trained to produce the product to the right standard.
DESIGN FOR ENVIRONMENT

Product designs can often have unintended environmental consequences, including:

  • High levels of waste through a lack of repairability. 
  • Damaging emissions during production.
  • Use of unsustainable materials. 
  • Potential to pollute after disposal. 
  • An unoptimised supply chain with a large carbon footprint. 

By bringing expert manufacturing teams into your design process you can ensure, from the outset, you are following best practice laid out in various environmental codes, including these standards and regulations:

Lean Project Management

When you partner with ESCATEC on a design project you will immediately benefit from our 40 strong engineering team based in Switzerland.

Our engineers are grouped into two highly competent teams with decades of experience between them. The first focuses on Design & Development while the second team focuses on NPI and product lifecycle management. The engagement and mix of engineers in any given programme are determined by the functional needs of the customer.

Effective project management is extremely important due to the technical services we offer. Project Managers are assigned based on their specific talents and experience; ranging from development of complex medical devices according to ISO13485 standards to industrialisation of new products across a range of market segments.

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Typically our Project Managers concentrate on one project at a time, which can range from several weeks through to a year. This level of focus enables them to fully immerse themself in each assignment and thereby build trust and a strong relationship with the customer.

To be successful, Project Managers must possess critical leadership, planning, and communication skills, they also need to be able to inspire teamwork and commitment in multi-disciplinary team members, and be knowledgeable about risk minimisation strategies in order to strike an effective balance between all stakeholders i.e. the customer, suppliers, employees and management.

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  • Verification & Validation

Are your product requirements met? Does the product work as it is supposed to? We ensure the design is compliant with all specifications and regulations.




  • Value Assessment & Engineering

Our value assessment and value engineering processes maintain a profitable balance between your product’s cost and quality.

Value engineering seeks to reduce costs and increase the value of a product. Traditionally, teams have looked to cut costs during the design process, the NPI stage, and the production phase. But for ESCATEC value engineering does not mean reducing quality. Instead we look at the whole supply chain to analyse what savings can be made and unnecessary costs reduced.

RESOURCES

Outsourcing medical device design and development

How medical device developers can work with EMS providers for better New Product Introductions.

Medical Device Development Guide

Micro-Opto-Electro-Mechanical-Systems (MOEMS)

We continue to invest in cutting-edge technology to advance our approach to micro-optics-electro-mechanical-systems (MOEMS), to meet customer requirements for cost-effective advanced electronic products.

A typical MOEMS project at ESCATEC begins with a conceptual design and evolves through various phases until a robust production process and product is achieved.

We have demonstrable experience of delivering MOEMS services across several market applications, including micro-displays for military use, 3D Time Of Flight (TOF) cameras for measurement and space applications, highly efficient light engines, micro-assembly and miniaturisation for automotive pressure sensors and hearing aids, and highly precise light modules for ophthalmology use.

When designing an optimised MOEMS device one of the most important factors for robust functionality is a stable production process. This is where ESCATEC’s expertise as an integrated EMS service provider gives customers a competitive advantage.

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ESCATEC’s MOEMS capabilities involve integrating two major technologies: micro-electro-mechanical systems (MEMS) and micro-optics.

MEMS is applied for device miniaturisation and has a wide range of applications in sensors, actuators, robotics, accelerometers, microvalves, flow controllers, GPS systems, and component miniaturisation. Market applications include use in space, air, land and sea vehicles, as well as industrial, biotechnology, and consumer electronics.

We take pride in solving our customers’ challenges. It drives us to continually improve and enhance our capabilities and is why our customers value us as a key strategic partner.

Taking this a step further, MOEMS involves integrating MEMS and the ability to manipulate optical signals on a very small scale (micro-optics) as a structured process in batch processing similar to integrated circuits and using micro-machining.

At the production level, MOEMS technology is used to fabricate a wide variety of hi-tech devices such as optical switches, optical cross-connect, tuneable VCSEL, and microbolometers, using materials like silicon, silicon dioxide, silicon nitride, and gallium arsenide.

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BENEFITS

ESCATEC’S DESIGN & DEVELOPMENT SERVICES

  • Years of experience designing complex, best-in-class products
  • In-house expertise, from conceptual design to complex box build
  • Optimised product performance and resource utilisation
  • Early involvement of DfX
  • Expert industrialisation

New product introduction & Industrialisation

The New Product Introduction (NPI) process is arguably one of the most crucial elements of contract electronics manufacturing. We get your product to market fast – meeting your quality and expectations. We work with you to maximise results and achieve the best possible outcome. We remove risks and reduce costs so you can move to market confidently.

PROJECT MANAGEMENT TOOLS

Our use of advanced project management tools, including critical path analysis along with common-sense strategies such as attention to detail and frequent communication, guides customers through the NPI process.

ANALYSIS & REVIEW

Understanding and planning your requirements correctly from the start saves costly delays in manufacturing. Together, we discuss your outsourcing goals and target market needs, your design requirements and your product’s manufacturability. We review all supply chain aspects and apply Lean Six Sigma and Design for Excellence (DfX) processes.

SET-UP

Experienced Key Account Managers act as the interface between ESCATEC and our customers; however, we also encourage engineer-to-engineer communication. Your single point of contact tracks every aspect of your product - from materials, supply chain and human resources to machine settings, line parameters, PFMEAs and quality control plans. The result is a seamless transition into manufacturing.

INSPECTION & TESTING

We meet your specified levels of accuracy and test coverage, or if need be, we can define your entire testing strategy for you. Rest assured, we will ensure your product is launched with zero defects.

You will benefit from the knowledge and expertise of qualified test technicians and engineers who are well versed in flying probe and in-circuit testing, in addition to being able to implement customer functional test solutions, complemented by conventional bench test equipment and XTJAG boundary scan.

Flying probe testing

Flying probe testing is a popular solution for manufacturers working with smaller batch sizes. It is also frequently used when fixed test probe access is limited or impractical. A proven method of electronics manufacturing defect detection and prevention, flying probe testing also eliminates the requirement for dedicated fixturing. 

Flying probe testing uses a set of precision moveable test probes that directly access test points, vias, component pads, circuit interconnections and fine pitch parts. This means the technique is able to replace the need for a mechanical test fixture while also achieving test coverage similar that exhibited by in-circuit test (ICT).

  • Initial test program creation is fast & direct from CAD files
  • Removes need for bed-of-nails test fixture
  • Enables easy inspection of any PCB assembly
  • Ideal for low & medium volumes in addition to high board mix prototype applications

In-circuit test

Although relatively uncommon in small to medium volume manufacturing, ESCATEC offers full on-site in-circuit test, both analogue and digital, with vector-less test. Test fixtures and programmes are also produced on-site. For slightly larger volumes ICT is invaluable as a pre-cursor to functional test, reducing debug time and significantly increasing functional test yield.

Boundary scan

Boundary scan test is renowned as an extremely rapid test method, equipping manufacturers to debug and programme complex digital circuits. Our team uses cutting edge technologies from the likes of X-JTAG to deliver powerful Boundary Scan solutions.

Ideal for testing boards populated with complex ICs, boundary scan processes deliver in-circuit levels of test coverage and diagnostics. Access purely from the board edge, this is an extremely useful and non-intrusive test technology. In addition, most modern devices feature bus technology which effectively creates thousands of test points to test components and interconnections. Boundary scan testing is the perfect way to identify structural fault locations, even beneath BGAs, without requiring mechanical access to the circuit.

ESCATEC boundary scan benefits include:

  • Accelerate new product development
  • Reduce time-to-market
  • Fast & efficient test program generation is ideal for boards undergoing design revisions
  • Highly versatile; can be used across the board production process for design verification, in-system programming, testing & debugging

Functional test

Functional test is a core component of the majority of successful test strategies. While it is often possible to de-skill functional testing, it is also often the case that functional test makes the highest demands on a skills base in terms of diagnostics.

We have considerable expertise in designing and delivering efficient test and diagnostic solutions. Our experienced and highly qualified test engineers can develop functional test solutions in-house, or work with those provided by our customers.

All functional PCB testing is fully supported by extensive engineering diagnostics so you can be sure that tested boards will be totally compliant with supplied specifications.

By using functional testing, our customers not only verify board functionality, but also, provide confirmation that the PCB will perform in its application environment.

SUPPLY CHAIN MANAGEMENT

The availability and quality of raw materials and components can make or break a product. We make sure everything you need to manufacture your unique product is available as you expect – and with the quality and price you want. Our in-house design and procurement specialists support you by advising, evaluating and selecting components to ensure the continued success of your brand.

Supported by our engineering group, our procurement, supply chain, and logistics teams have the expertise to identify sourcing options based on the specific needs of each product and customer.

We seek to build long-term, collaborative relationships with our approved supplier partners around the world. This enables us to continually reduce the total cost of acquisition and supply chain complexity while still maintaining the highest levels of quality and delivery.

Through an intensive and comprehensive supplier relationship management (SRM) programme and close management of interactions, the value of our supplier relationships is maximised to benefit our customers.

Moreover, with product life-cycles becoming shorter each year, especially within the semiconductor market, thousands of components become obsolete and therefore component obsolescence requires continual vigilance. At ESCATEC, we have significant expertise in all aspects of obsolescence management and work closely with key partners to provide up to date and extensive information to customers. With early warning processes in place to identify ‘at-risk’ parts, we can perform obsolescence risk analysis before a part has been discontinued and plan the transition to a replacement device or identify sources of the device that is becoming obsolete as appropriate in each case in conjunction with our customer’s needs.

Our expertise in ensuring that customers’ Bills of Materials (BOMs) are accurate and complete is supported by sophisticated audit and analysis tools that provide customers with the confidence that they will be kept fully aware of component life cycle information. Our knowledge and close monitoring of markets ensures that we are able to adapt our supply chain to changes in market conditions with speed and agility.

VALUE ASSESSMENT & ENGINEERING

Value Engineering is a systematic process of investigation, analysis, and recommendation for intelligent cost reduction that will drive enhanced value for your customers and increase your profitability. Our value assessment and value engineering processes maintain a profitable balance between your product's cost, quality, and functionality.

Value engineering seeks to reduce costs and increase the value of a product. Traditionally, teams have looked to cut costs during the design process, the NPI stage, and the production phase. But for ESCATEC value engineering does not mean reducing quality. Instead, we look at the whole supply chain to analyse what savings can be made and unnecessary costs reduced.

WORKSHOPS

We work with you collaboratively to reduce your costs by optimising your electronic and mechatronic design and manufacturing process.

Our experts analyse your idea, design or product and provide you with detailed suggestions for improvement

Our workshops:

  • Help reduce costs while maintaining or improving performance and quality
  • Can be applied to existing products out in the field and also those in the design phase
  • Lead to improvements in both product and process

Depending on your requirements, a typical 2 day workshop costs between 2000 USD and 6000 USD. For an exact quote tailored to your needs, contact us today. 

 

BENEFITS

NPI & INDUSTRIALISATION

Understanding your business and meeting your needs.

  • We help you launch your design fast to market
  • Our process analysis tools and quality control plans eliminate risk
  • Lean Six Sigma reduces waste and lowers your costs
  • Experienced Supply Chain Managers ensure quality, availability and best cost