Each began with a plant, a product line or an import bill that was not working. What follows is the situation, what was actually done on the floor, and where it ended up.
One of India's first automated SMT operations, built from nothing in-house.
Challenge
Surface mount had barely arrived in the country. The brief was automated tuner assembly with no existing expertise, equipment or process to inherit.
What we did
- Trained on the technology in Japan and Taiwan
- Commissioned the lines and supporting infrastructure
- Wrote the quality systems and operating procedures
- Recruited and trained over 50 people
Result
Stable commercial output at consistent quality, and a manufacturing base that everything afterwards was built on.
A plant below survival volume, turned into a growth business.
Challenge
Output was falling and morale with it. Volumes had dropped below the level needed to keep the operation viable, and customers were losing patience.
What we did
- Reorganised teams and put accountability back in place
- Opened technology partnerships overseas
- Widened the portfolio to match what buyers wanted
- Reworked sourcing and floor practice
Result
Volume grew forty-fold, customer confidence came back, and the plant moved from rescue to expansion.
Cable, satellite and fibre products, brought home and then sent back out.
Challenge
Cable television, satellite and fibre optic equipment came almost entirely from abroad. Domestic capability to design or build it barely existed.
What we did
- Identified the technologies worth licensing and secured the partners
- Localised the designs and the processes behind them
- Stood up domestic production and test capability
- Built the cross-functional teams to run it
Result
Several product categories moved to local manufacture, reached customers across the country, and went on to ship overseas.
Through-hole to surface mount, with the business case to carry it.
Challenge
Products were still built on leaded assembly. That meant larger housings, heavier material cost, slower lines and a widening gap against competing designs.
What we did
- Made the investment case before touching the line
- Introduced reflow assembly and controlled environments
- Put ESD discipline and SMD handling practice in place
- Trained the teams through the changeover
Result
Smaller products at lower cost with higher first-pass yield, a clear return on the spend, and an organisation willing to adopt the next thing.
Set-top boxes that were going to be imported, made on a local line instead.
Challenge
The plan was to buy finished units abroad. Nobody believed fine-pitch placement, BGA, programming and test could be held to standard locally.
What we did
- Studied how it was being done internationally
- Built the SMT, programming and test capability in-house
- Developed the teams through structured capability work
- Grew a local supplier base around the line
Result
A full switch from import to local build, with low field failure rates, lower landed cost and customers who stayed.
If any of this looks like your situation, we should talk.
All of these were hands-on engagements, on the floor with your people, until the numbers held.
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