SOLUTION

New Product Introduction

New Product Introduction (NPI) is a structured industrialisation process that helps OEMs move from design and prototype builds into repeatable, scalable manufacturing. It reduces launch risks, shortens time-to-market, and ensures a controlled production plan for quality, testing, and supply chain readiness.

NPI with ESCATEC

ESCATEC’s NPI offering helps you maximise results, remove risks, reduce costs, and move to market confidently by turning a design into a controlled manufacturing process. It’s designed for OEM teams preparing for industrialisation, when quality, testing coverage, and supply chain readiness must be right the first time.

Key facts at a glance

Faster, more predictable launch planning using critical path analysis and frequent communication.
Earlier DfX (Design for Excellence) and Lean Six Sigma input to reduce waste, cost, and surprises during ramp-up.
Manufacturing set-up with defined PFMEAs, line parameters, and quality control plans.
Testing capabilities spanning flying probe, in-circuit, customer-provided functional test solutions, bench test equipment, and XJTAG boundary scan.
Supply chain readiness with sourcing options, availability and quality aligned to your product and market needs.

From prototype to mass production

How does ESCATEC’s NPI Process work?

ESCATEC runs NPI as a phased, cross-functional process that starts with planning the work, then validating manufacturability and test, and finally setting up production controls so the transition into manufacturing is seamless.

Project management

We leverage advanced project management tools, critical path analysis, attention to detail, and frequent communication to plan and manage effectively.

Analysis & review

We discuss your outsourcing goals and target-market needs; review design requirements and manufacturability; review the supply chain; and apply Lean Six Sigma and DfX.

Manufacturing set-up

With a Key Account Manager as the interface, we encourage engineer-to-engineer communication and track materials, supply chain, human resources, machine settings, line parameters, PFMEAs, and quality control plans.

Inspect & test

With the option to define a full test strategy for you, we implement flying probe/ICT/functional test solutions (plus bench equipment and XJTAG) to meet your required accuracy and test coverage.

Supply chain readiness

Our procurement and logistics teams identify sourcing options to ensure components are available at the expected quality and price; our in-house design and procurement specialists then advise and select components in line with your expectations and objectives.

Value assessment & engineering

We systematically apply Value Engineering to investigate, analyse, and recommend cost reductions across the entire supply chain, maintaining a profitable balance between cost, quality, and functionality.

Why partner with ESCATEC for NPI?

ESCATEC achieves effective NPI through disciplined project control, engineer-to-engineer and cross-team collaboration, and an integrated approach to testing and supply chain, so you avoid surprises and costly delays during industrialisation.

What sets our NPI apart:

Project discipline: Our critical path analysis and frequent communication guide customers seamlessly through the NPI process.
Integrated team model: Our Key Account Managers & Business Unit Managers keep communication lines open from day one, and our project team is integrated across design & development, prototyping, testing, and manufacturing.
Test breadth: We combine flying-probe, ICT, functional test solutions, bench equipment, and XJTAG boundary-scan to ensure your product is launched with zero defects.
Supply chain & engineering alignment: We have engineering-supported procurement and supply chain management to identify sourcing options and keep quality, availability, and cost in alignment, always.
Value Engineering without quality reduction: Our Value Engineering process does not reduce quality, but optimises across the whole supply chain.

When to consider ESCATEC’s NPI solutions

NPI from ESCATEC is a good fit when you need:

Prototype-to-production support (including rapid iteration and pilot learning)
DfX input before ramp-up
A test strategy that matches your coverage and accuracy requirements
Supply chain evaluation and sourcing alignment to the target market

Ready to discuss an NPI?

What industries and product types does ESCATEC support?

We offer NPI and industrialisation for the Industrial, Medical, and Transportation sectors, across a broad range of electronics and mechatronic products—from PCBAs to complete systems—backed by services that extend into box build, machining, injection moulding, microelectronics and post-production.

OUR DESIGN, DEVELOPMENT, AND MANUFACTURING SERVICES

We offer comprehensive EMS services for OEMs looking to scale their business by outsourcing design & manufacturing.

Design, Development & DfX

Engineering support to improve manufacturability, testability, and  production readiness.

New Product Introduction

Structured NPI to move products from development into controlled production.

Manufacturing Capabilities

Prototyping, PCBA, microelectronics, box build assembly, mechatronics, machining, and injection moulding.

Test Solutions and QA

Test approaches to support verification and quality control during manufacturing.

Supply Chain Management

Procurement and supply chain coordination for build continuity.

Value-Added Post-Production Services

Servicing, repair, lifecycle management,  and logistics.

Hover over infographic to find out more

Design & Development

New Product Introduction

Supply Chain Management

Plastic Injection Moulding

Test Solutions

Post Production

NPI timelines and typical engagement models

NPI timelines depend on design maturity, component availability, and test strategy complexity; ESCATEC focuses on removing avoidable delays by planning correctly from the start and managing the critical path.

What you can standardise upfront to speed up the process:

Design package readiness (Gerbers, BOM, schematics, test requirements, mechanical drawings)
Prototype/pilot approach (Prototype volumes, pilot build expectations, ramp gates)
Test approach (flying probe vs ICT vs functional test and coverage targets)
Supply chain risk plan (alternates, obsolescence, lead-time risks; AVLs or approved sourcing)

ESCATEC Sdn. Bhd. (HQ) ESCATEC Electronics Sdn. Bhd. ESCATEC Medical Sdn. Bhd. ESCATEC Technology Sdn. Bhd.

Industrial Zone 4, 11900 Bayan Lepas, Penang, Malaysia

+60 4 643 2554

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Ready to start an NPI engagement with ESCATEC?

If you have a product to take to market, our experts can analyse your idea, design, or product in an ESCATEC NPI workshop and provide you with detailed suggestions for improvement.

This collaborative session helps you reduce your costs by optimising your electronic and mechatronic design and manufacturing process.

Reduces costs while maintaining or improving performance and quality
Applicable to existing products in the field as well as those in the design phase
Improves both product and process

We start by aligning your outsourcing goals, target market needs, and design/test readiness together, then ESCATEC scopes your NPI plan, risks, and the right mix of testing and supply chain support.

A typical 2-day workshop costs between 2000 USD and 6000 USD, depending on your requirements.

GET A TAILORED QUOTE

CASE STUDY

99.99% success rate for Controlant

ESCATEC were able to drive the rapid scaling of component manufacture for Controlant, facilitating the largest and fastest global vaccine roll out in human history.

LEARN MORE

NPI FAQs

1. Can ESCATEC take my product from prototype to full production?

Yes. ESCATEC’s NPI integrates planning, manufacturability review, production set-up, testing, and supply chain readiness so you can transition into manufacturing with fewer surprises. The same teams can support ongoing services such as PCB assembly, box build, and test solutions as you scale.

2. What testing options are available during NPI?

ESCATEC supports flying probe and in-circuit testing, can implement customer functional test solutions, and complements these with conventional bench test equipment and XJTAG boundary scan. You can specify required accuracy and coverage, or ESCATEC can help define the testing strategy.

3. How does ESCATEC reduce supply chain risk during a new product launch?

ESCATEC reviews all aspects of the supply chain early and uses procurement, supply chain, and logistics expertise—supported by engineering—to identify sourcing options that fit your product and customer needs. The goal is to ensure parts are available at the quality and price you expect before ramp-up.

4. What is included in ESCATEC’s Value Engineering process during NPI?

Value Engineering is a systematic, structured process to find intelligent cost reductions while maintaining balance between cost, quality, and functionality. ESCATEC leverages Value Engineering to optimise manufacturability, not reduce quality, by analysing the whole supply chain to reduce unnecessary costs.

5. Do you offer workshops to improve manufacturability and cost?

Yes. ESCATEC runs collaborative workshops to optimise your electronic and mechatronic design and manufacturing, providing detailed improvement suggestions. Depending on requirements, a typical 2-day workshop costs between 2000 USD and 6000 USD.

RESOURCES

The definitive guide to test within electronics manufacturing

Why testing should be at the heart of everything you do

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ESCATEC's manufacturing capabilities are complemented by enhanced support services for our clients, such as design and development support, test solutions, sophisticated supply chain management, postponement manufacturing and direct-ship outbound logistics.

PCB Assembly

We support customers from the prototype and industrialisation stages, through to the ongoing manufacture of complex, multi-technology PCBAs, in low, medium and high volumes.

Box Build Assembly

We're experts in complex sub-assemblies and finished, tested, products. We offer turnkey electronics, mechatronics, cabinet assembly, system integration & test solutions.

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Mechatronics

ESCATEC offers a wide range of mechatronics solutions and supply chain experience - everything from ‘benchtop’ products through to ‘large format’ electro-mechanical machines.

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Machining

From simple CNC turned components to elaborate CNC milled assemblies, we cater to diverse sectors, including industrial electronic, transportation and medical device manufacturing.

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Test Solutions

A proven method of electronics manufacturing defect detection and prevention, flying probe testing also eliminates the requirement for dedicated fixturing.

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Plastic Injection Moulding

At ESCATEC we use cutting-edge technology and equipment, to ensure that every injection moulding project we undertake meets the highest standards of quality and precision.

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Microelectronics

Our experienced teams design, develop and manufacture high performance LED, laser, and lighting solutions. We ensure micro-optic needs for complex MOEMS products are met and delivered.

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Design & Development

We specialise in electronics, software, mechanical, and system design and development. Following Design for eXcellence (DfX), Design for Manufacture (DFM), and VA/VE best practices, we turn your ideas into market-ready products.

New Product Introduction

Our unmatched NPI support is characterised by lean project management, comprehensive testing, robust supply chain management, and close collaboration with your teams to minimise risks, maximise results, and ensure product quality.

Supply Chain Management

With our established global supplier partnerships, our experienced procurement, SCM, and logistics teams can identify the best sourcing options based on your needs. We supply a vast range of products to various sectors reliably and cost-effectively.

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Prototyping

With our prototyping services, we are with you every step of the way, from schematic design to functional testing and validation. We work with you to refine your designs, creating a high-quality final product ready for mass production.

Post-production

Whether you’re launching a new and improved product iteration or extending the lifecycle of your existing in-market products, our post-production capabilities help to maximise profits and keep you ahead of the competition.

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