Our process explained in detail

Search for appropriate suppliers for the required manufacturing process.

Conduct supplier audits covering technical capability, financial stability and managerial transparency.

Assess relevant quality and compliance systems, including ISO 9001, IATF 16949, ISO 14001, ISO 45001 and AS9100 for aerospace and defense applications, where applicable.

Categorize suppliers by appropriate tier or capability level.

Review the age and condition of manufacturing equipment.

Verify calibration of inspection and measurement equipment through NABL-accredited laboratories where applicable.

Review previously executed orders, customer references and supplier performance records.

Review workforce skill matrices to assess actual technical capability.

Assess readiness for applicable local regulatory and governmental compliance requirements.

Validate production capacity against customer requirements using value stream mapping where appropriate.

For large-volume programs, evaluate the use of multiple suppliers based on metrics such as OEE, capacity utilization and volume flexibility.

Conduct DFMA reviews where appropriate.

Use project schedules and Gantt charts to monitor major milestones from tooling kickoff through T1 samples and mass production.

Conduct first-part or T1 inspection according to customer requirements using appropriate methods such as manual inspection, CMM, profile projection and spectrometry.

Produce and evaluate pilot batches following T1 sample approval.

Begin mass production following pilot-batch approval.

Perform continuous in-process and final inspection.

Prepare PPAP documentation where required, including design and change documentation, risk analysis and controls, validation results, documentation and samples, and the Part Submission Warrant (PSW).

Apply appropriate quality-control tools, including fishbone diagrams, check sheets, control charts, histograms, Pareto charts, scatter diagrams and process flow charts.

Apply DFMEA and PFMEA where required.

Track order execution using appropriate production-management and data-management systems, including MES and digital manufacturing tools where applicable.

Establish first-article inspection protocols.

Define in-process and final inspection checkpoints.

Manage defect resolution using methodologies such as 8D.

Generate required quality reports, including SPC and SQC documentation where applicable.

Prepare process and quality documentation, including APQP documentation and detailed quality and process plans.

Generate applicable physical and functional test reports, including CMM, spectrometry, coating and dimensional inspection reports.

Prepare products for export according to customer requirements and applicable international packaging standards.

Use ESD-protective packaging for electronic components where required.

Use VCI films or bags and appropriate corrosion-preventive oils for metal parts where required.

Use desiccants such as silica gel where moisture protection is required.

Coordinate applicable customs, technical and regulatory documentation, including certificates of origin, environmental documentation, GST-related documentation and RoHS compliance where applicable.

Coordinate with freight forwarders and logistics providers.

Monitor takt time where relevant.

Monitor supplier adherence to applicable good manufacturing practices.

Establish and validate an effective supplier and customer feedback system.

We use a structured engineering process across reverse engineering, new product development and manufacturing support to reduce errors, simplify revisions and produce documentation for a seamless transition into production.

We create fully parametric CAD models in which an applied understanding of functional relationships is expressed in terms of driving and driven parameters rather than treating dimensions as isolated values so that engineering changes propagate consistently through the project, drastically reducing errors introduced by change orders.

We employ a structured, formal parametric nomenclature of our own devising that allows our CAD assembly models to read cleanly like code, making components, dimensions, parameters and formulas easier to understand, maintain and modify as designs evolve — especially in the most complicated assemblies.

We select and document materials based on function and customer requirements.

We establish relationships between components including clearance and various types of fits.

We apply GD&T according to the functional requirements of the assembly and the manufacturing processes used to produce it.

We define coatings, plating, heat treatment, surface finish and other finishing requirements where applicable.

We produce manufacturing drawings, bills of materials, specifications and other technical documentation required for procurement and production.

We review designs for manufacturability and assembly, including opportunities to reduce part count, simplify production and control cost.

We prototype or produce validation batches where appropriate before committing to production quantities.

We inspect and test prototypes or validation batches using appropriate dimensional, material, functional and performance testing methods.

We incorporate validation results and engineering changes into the parametric model and production documentation.

We develop inspection and quality-control requirements appropriate to the product, production process, volume and customer requirements.

Identify and document the materials used in the existing product, using appropriate analytical methods such as spectrometry where required.

Identify coatings, plating, heat treatment, surface treatments and other finishing processes, including surface finish and other cosmetic requirements.

Disassemble, inspect, and measure the product to determine how individual components function and interact within the assembly.

Create a fully parametric CAD assembly model based on the functional relationships between components rather than simply reproducing measured dimensions.

Identify critical dimensions and relate dependent dimensions through formulas so that engineering changes propagate through the model consistently and with reduced risk of error.

Apply our structured parametric naming system so that dimensions, parameters and component relationships are clearly organized and the CAD model can be read and maintained through our proprietary software much like well-structured code.

Determine functional interfaces between components, including clearance, transition and interference fits as appropriate.

Apply geometric dimensioning and tolerancing (GD&T) based on the functional requirements of the assembly and the manufacturing processes to be used.

Produce manufacturing drawings, specifications and other technical documentation required for prototype production.

Procure and manufacture a small validation batch before committing to production quantities.

Inspect and test the validation batch using appropriate dimensional, material, functional and performance testing methods to confirm that the reconstructed product operates as intended.

Resolve any design, tolerance, material or manufacturing issues identified during validation and update the engineering documentation accordingly.

Develop an appropriate quality-control and inspection plan based on the product, production volume, critical characteristics and the client's requirements.

Proceed to production quantities only after the engineering, prototype validation and quality-control requirements have been successfully completed.

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