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Our Work: New Product Introduction



How Sypris collaborated with a customer to successfully launch a new product

Background

A customer needed a manufacturing service provider to help them build products that were in early development, incorporate in-process design and test changes, and a process to support new product introduction through full-scale production.
Sypris was selected for this program based on our technical, operational and supply chain experience and proven results with similar complex program launches. 

Product Complexity

The products were high-density circuit card assemblies integrated into multiple module level assemblies. The product was highly complex, having a multi-level BOM structure with over 2000 parts consisting of 300 unique part numbers. The electronic component assembly included 0402 chip components, BGAs, transformer windings, high power connectors, fiber optics and high-density data bus connectors. The mechanical component assembly included heatsinks, wedge locks, thermal spreader pads, jumper wires, cable harnesses and rigid flex assemblies.

Approach

Sypris established a cross-functional team for the program utilizing our “lean launch” approach to ensure the success of the project and to define additional value opportunities for the customer. Given the products were early in their life cycle, we tailored a flexible approach to our customer needs. We conducted a PFMEA to define technical and program risk and collaborated with our customer to mitigate the risks over the course of the product launch.
Sypris developed and implemented a dedicated assembly and test cell that was flexible and could easily adapt to changing customer requirements as the product design matured. Some of the unique processes developed by Sypris included thermal vacuum bonding, additive manufacturing using ESD safe media, conformal coating with intricate keep-out zones and module-level functional test sets.
Sypris established a material sourcing and management plan for each component on the BOM and provided value-added services. Throughout the program development and build, Sypris proposed specific recommendations for product cost reduction and schedule risk mitigation for the customer’s consideration.

Result

Sypris completed all engineering development requirements and product deliveries on time and met the customer’s expectations. Sypris also completed upwards of 100 engineering changes successfully while continuing to produce products at multiple revision levels to meet customer expectations.
Sypris was subsequently awarded a follow-on limited-rate production order for this family of products as well as a multi-year full-rate production order on an exclusive basis.

 

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