C-01Harness & connector alternatives
RF connector alternative plus LV harness consolidation
Client type: German Tier-1 (infotainment and antenna systems)
Starting problem
FAKRA / Mini-FAKRA connectors had long lead times and high prices; the alternative had to fit the existing PCB layout and assembly tooling unchanged.
What we did
- 01Extracted the parameters that must match from the original datasheet: mating force, impedance, shielding attenuation, thermal cycling
- 02Built samples at three audited connector plants and ran comparative testing (impedance, salt spray, vibration, thermal cycling)
- 03Bundled the alternative connector with the LV harness into one supply package to cut the client's supplier count
- 04Issued PPAP and control plan, with tightened sampling for the first three months of production
Outcome
The alternative passed the client's lab release and went to serial production; cost dropped sharply and lead time moved from imported weeks to domestic weeks.
- Connector cost
- -32%
- Lead time
- 14 weeks → 4 weeks
- Validation to SOP
- 12 weeks
- First-year PPM
- < 50
C-02PCBA / EMS
Automotive PCBA transferred from Europe to the Yangtze Delta
Client type: European Tier-2 (body control electronics)
Starting problem
European contract manufacturing was expensive and capacity-limited, but the client feared a quality break and component compliance risk after the transfer.
What we did
- 01Reviewed the BOM for automotive grade and lifecycle, flagged EOL and single-source parts, proposed alternates
- 02Screened three IATF 16949 EMS plants, audited on site, assessed real capacity and nominated one
- 03Ran a DFM review to optimise panelisation and test points, rebuilt the ICT/FCT concept
- 04Staged ramp-up: engineering samples → pilot lot → serial, with a quality gate at each stage
Outcome
The transfer closed within a quarter with serial yield above the original site, plus full batch traceability and an annual audit cycle.
- Piece cost
- -25%
- Transfer duration
- 13 weeks
- First pass yield
- 99.2%
- EOL parts resolved
- 7 part numbers
C-03Tooling & structural parts
Large injection tool development and transfer to serial parts
Client type: Tier-1 supplier to a European OEM (interior structural parts)
Starting problem
A large part with uneven wall thickness warped out of tolerance in the original concept, and the client required tool ownership with the option to relocate later.
What we did
- 01Mold-flow analysis to re-position gates and cooling channels, rib layout adjusted to control warpage
- 02Nominated a toolmaker with large-tonnage presses; ownership, tool life and relocation clauses written into the contract
- 03Attended T0–T3 trials on site with dimensional reports and closed-loop corrective actions
- 04Set up first-article inspection and SPC on critical dimensions for serial production
Outcome
Full dimensional conformity was reached at the third trial; tool ownership and drawings were handed over, and serial dimensions stayed stable.
- Tool development
- 10 weeks to T0
- Trials to conformity
- T3
- Critical dimension CPK
- ≥ 1.67
- Tool ownership
- Client-owned, relocatable
C-04BLDC motors
Dual sourcing for BLDC motor assemblies
Client type: European actuator manufacturer (domestic and automotive)
Starting problem
Single-source dependency was unacceptable, but a second source could not widen the performance band.
What we did
- 01Derived a quantified acceptance spec from the running part: speed–torque curve, noise, endurance
- 02Developed the second supplier with comparative testing on a unified test bench and pass criteria
- 03Ran both suppliers on one control plan with quarterly cross-comparison
Outcome
The second source reached serial production within half a year, with matched performance bandwidth and materially lower supply risk.
- Second source qualification
- 24 weeks
- Performance deviation
- < 3%
- Noise requirement
- Fully met
- Supply risk
- Single point removed
C-05Supplier audit
Standalone assignment: VDA 6.3 audit and capacity verification
Client type: German mid-size Tier-1 (purchasing department)
Starting problem
The client had shortlisted a plant but could not send staff to China to verify capacity and system maturity.
What we did
- 01On-site audit in VDA 6.3 P2–P7 structure, with ESG and working-hours spot checks
- 02Calculated usable capacity from equipment list, shifts and utilisation instead of self-reported numbers
- 03Delivered a findings list with risk ratings and deadlines, then tracked closure
Outcome
Two high-risk findings changed the client's nomination decision and their ramp-up plan.
- Turnaround
- 2 weeks incl. report
- Findings
- 2 high / 6 medium
- Report structure
- VDA 6.3 + ESG annex
- Corrective closure
- 8 weeks
C-06Logistics & delivery
Consolidated shipping and JIT replenishment across categories
Client type: European Tier-1 (multiple receiving plants)
Starting problem
Harnesses, structural parts and electronics shipped separately from different plants, driving freight cost and unpredictable arrivals.
What we did
- 01Consolidated shipments via Shanghai and Shenzhen hubs with unified documents and origin certificates
- 02Set safety stock and replenishment triggers to the client's line takt
- 03Introduced rolling monthly forecasts with deviation reviews
Outcome
Freight cost dropped, on-time delivery improved and line stoppages from missing parts went to zero.
- Freight cost
- -18%
- On-time delivery
- 98.6%
- Line stoppages
- 0 in 12 months
- Safety stock cover
- 3 weeks
Tell us the category, annual volume and target market and we will share the closest execution path plus verifiable references.