The client was actively seeking a local manufacturing partner to optimize their operations and drive greater efficiency. Their existing production strategy involved a hybrid approach, utilizing both in-house resources and a contract manufacturer located in the Midwest. However, this setup presented challenges in coordination, lead times, and overall scalability, prompting them to explore a more seamless and geographically accessible solution to better align with their operational goals.

Manufacturing Challenge

Copy Exact Requirements

Requires adherence to a strict “copy exact” policy, covering material sourcing, fabrication, assembly, testing, and all other processes to ensure absolute product consistency. 

Ultra-Clean Environment

The build environment was enhanced by establishing it in an open Class 100 area, equipped with point-of-use ionizers to effectively eliminate static attraction and prevent particle accumulation.

Serial Number and Test Data Integrity

All key serialized components are recorded in a database residing in our MRP system for each lamp produced along with all test data log files traceable to each lamp.

Personnel Safety working with Energized Lasers

Testing requires strict safety protocols with energized lasers. Operators wear wavelength-specific eye protection and conduct tests in a secure clean room test area to prevent accidental exposure.

Systems Assembly Process

Step 1: Precision Fabrication Group

Adhering to strict “copy exact” guidelines, the team initiated a project to produce machined qualification samples for customer approval. In six months, they transitioned nearly all machined components from outsourced production to in-house manufacturing. This shift ensured complete control over the process and an uninterrupted supply of 10 critical high-tolerance components.

Step 2: SMG Usage

The production cell was strategically established in a dedicated section of the Class 100 clean room, with primary inventory stocked at the point of use for maximum efficiency. A specialized test area was also integrated within the clean room, enabling seamless assembly, testing, and packaging while maintaining strict adherence to cleanroom protocols.

Step 3: Supply Chain Management

Our materials team uses proactive forecasting, securing long-lead items like PC boards, beamline optical components, electronics, and custom parts 12 to 18 months ahead. This strategy ensures seamless production, testing, and shipping based on a managed “open order report,” while allowing us to swiftly adapt to sudden demand changes, often within 1-2 weeks.

Innovent Solution

When the client initially approached us their production model relied on a combination of in-house manufacturing and a remote contract manufacturer (CM) located in the Midwest. However, inefficiencies with the remote CM led them to actively seek a local partner.

Being just 30 minutes away, we were invited for consideration. Following a tour of our facility, a thorough review of our resources and capabilities, and an extensive vetting of our processes, we were selected to participate in co-build training with the client.

After a successful co-build, we replicated the client’s build cell strategy and introduced significant improvements, including the integration of PC monitors at workstations to display relevant build procedures and an automated serial number database for real-time updates during production.

We further enhanced the build environment by establishing operations in an open Class 100 cleanroom, equipped with point-of-use ionizers to prevent static attraction and particle accumulation.

The Midwest CM was phased out, and all specialized tools and fixtures were relocated to our facility. We conducted a series of supervised co-builds to ensure our processes met the client’s stringent quality standards.

By the conclusion of this transition, full production was transferred to us. Since then, the partnership has grown from manufacturing a single lamp model to four active models, along with additional components for other product lines not requiring a cleanroom environment.

In-House Capabilities Utilized

1. Precision Fabrication - CNC Machining of housings, covers and heat sinks.
2. Orbital Tig Welding - process gas tube runs for several different gas box assemblies.
3. Clean Room Assembly - Laser driven light sources are assembled, tested, and packaged.

Business Impact

This partnership enabled the client to significantly expand their production capacity without the need to invest in new facilities or infrastructure. By transitioning production to our fully equipped facility, the client was able to scale operations quickly and efficiently.

They benefited from our advanced manufacturing capabilities, cleanroom environment, and experienced team, which provided the flexibility to meet growing demand without the upfront capital expenditures associated with building or upgrading their own facilities. This approach not only streamlined their operations but also allowed them to focus on their core business while we managed the complexities of production scaling.

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This case study was originally posted to Innovent.