Leveraging decades of experience across hundreds of projects and thousands of assemblies to create a total solution that addresses your unique outsourcing challenges

Simply put, we’ve been doing this for a long time. Working with some of the most demanding OEMs in the computer, industrial, defense, aerospace, and medical industries, we’ve been exposed to some of the most difficult problems you can imagine. Likewise, we’ve also been part of some extremely innovative solutions. We bring that expertise to every one of our engagements, offering insights that you might not have considered. Our integrated solution will address the entirety of your complex outsourcing environment.

Some of the challenges our customers have faced:

Today’s competitive landscape requires a laser focus on your true core competency, the elements of your value proposition that are most closely linked to your success. Outsourcing to a qualified and responsive EMS provider frees up your resources so that they can be allocated to that which differentiates you from your competition and strengthens your competitive advantage. Federal Electronics has developed processes that methodically and systematically manage the transition from internal manufacturing to an outsourcing model in a controlled environment, minimizing the drain on your administrative and engineering resources while eliminating risk. Whether you’re outsourcing a portion of your manufacturing process or the entire product, Federal Electronics has extensive experience assisting a wide range of companies, from small businesses to Fortune 500 organizations.
Scaling production to support an accelerating revenue stream can elicit feelings of excitement and fear at the same time. Whether you’re building product in-house and have reached the limits of your capacity or you’ve outsourced and are exposed to the limitations of one supplier, developing another source to alleviate potential production constraints during times of rapid growth requires a disciplined and thoughtful response. Having extensive experience scaling new projects through expedited demand cycles, we’ve established bulletproof program launch processes that accelerate the product through first article validation and into volume production quickly and efficiently.
Contemplating the re-sourcing of product from an incumbent EMS provider to another manufacturer carries with it a certain element of risk. But when delivery, quality, or cost performance has reached the point where it becomes an impediment to your continued success and growth, moving production becomes a necessity. Federal Electronics recognizes that there are unique challenges when moving away from an incumbent supplier, including the potential for institutional manufacturing knowledge possessed by the supplier that might not exist in your documentation, alternate sourcing of components that may not comply with your approved vendor list, and the need to move tooling or fixtures. Perhaps most concerning is the distinct possibility that the supplier may reassign resources once the decision is made, jeopardizing your existing product flow. We understand the risk and work closely with our customers to develop and implement a re-sourcing strategy that accelerates the transition process and considers contingencies should any of these potential scenarios become reality.
While every product must comply with the appropriate specifications and standards, certain industries are subject to particularly stringent quality requirements or regulations. This is especially true when non-conformance can result in catastrophic failure, such as in the medical, military, and aerospace industries. Federal Electronics’ ISO 9001:2008, AS9100, and ISO 13485 registered Quality Management System addresses the specific requirements mandated by each market. Our traceability programs ensure identification down to the component lot code, and our vertical integration model ensures serial number tracking for each sub-assembly right through to the finished product. We’ve also implemented a robust counterfeit materials program that complies with the SAE AS5553 standard, minimizing the risk of sub-standard material entering our supply stream.
If your requirements can be accurately defined as low-to-mid volume, higher mix (many unique assembly part numbers), and higher complexity, then you face multiple challenges that require a comprehensive solution across manufacturing, engineering, supply chain, and administrative functions. Federal Electronics’ infrastructure, best described as the combination of our systems, software, processes, and people, has been specifically designed to address every aspect of those challenges. Expertise gained from participating in best practices implemented across multiple industries is leveraged to your advantage. Our vertical integration business model – designed to accommodate the potentially disruptive environment inherent in this market segment, coupled with our ability to rapidly launch projects, shift direction, and scale in both directions – brings products to market quicker without sacrificing performance.
Many of our customers never considered low-cost, near-shore region sourcing for their lower volume, higher complexity products, and with good reason. Much of the production sourced in Mexico is for higher volume, lower mix, and lower complexity projects. Federal Electronics has shifted the paradigm by creating a business model that justifies near-shore production based upon labor content rather than just volume. Our production facility in Hermosillo, Sonora Mexico is structured for repeatable manufacturing of high labor content assemblies, sometimes in volumes as low as 1 or 2 units per month. Using a hybrid approach, we’ll craft a manufacturing strategy that leverages the production of highly complex, labor intensive assemblies within the lower production costs of Mexico. Where needed, we’ll integrate into larger, higher complexity boxes and frames in our domestic facility, effectively reducing costs without sacrificing quality and reliability.

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