Service Capabilities

Developed For Your Critical Challenges

End-to-End Excellence in Electronics Manufacturing

Federal Electronics’ services are the foundational elements of a custom configured solution for your unique requirements.

Electronics Manufacturing Service - New Product Introduction (NPI)
New Product Introduction (NPI)
Electronics Manufacturing Service - Supply Chain & Logistics
Supply Chain & Logistics
Electronics Manufacturing Service - Manufacturing Services
Manufacturing Services
Sustaining Services

New Product Introduction (NPI)

Rapidly Taking Your Ideas to Market

Our New Product Introduction (NPI) methodology is designed to move as rapidly and seamlessly as possible, from prototype, through NPI, to scaled manufacturing. Our decades of electronics manufacturing experience have taught us the importance of a dedicated project launch team, focused on your budget and your deadline, working closely with your staff to make your new product a reality.

Business Objectives: We work with your team to identify cost and timeline objectives.
Technical Data Package Review: Assess initial technical data package to ensure all required information is available and in the proper format.
Detailed Gap Analyses: Our process identifies unique project requirements that may exceed industry standards, reducing the potential for unexpected misalignments.
Single Point of Contact: A dedicated NPI Program Manager coordinates all internal activity, aligning our resources with your objectives.
Team Approach: Subject matter experts from engineering, supply chain, manufacturing, and quality assurance assemble resources based on project scope and configuration.
Seamless Integration: Our team becomes a virtual extension of your operation.
Custom Report Formats: “Action Registers” configured for your project requirements are maintained by your NPI project manager and serve as the baseline for all communications.
Periodic and Structured Reviews: Defined and scheduled project reviews that provide the basis for resource allocation and constraint management to drive progress.
Design Assist (DFx): Value added engineering assistance to optimize your product for cost and manufacturability, validate supply chain sourcing decisions, improve process development, while collaborating with your design engineering team.
Prototyping: For early engagement opportunities, our prototyping capability validates manufacturability, accuracy of BOM, and functionality of product design.
Pre-Production Product/Process Verification: Through a robust first article process, we verify BOM and costs, finalize documentation package, and prepare for production.
Early Risk Identification: We identify risks and exposures early in the process so that solutions can be quickly incorporated.
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Supply Chain & Logistics

Flexible, Integrated Supply Chain for Cost-Competitive Advantage

In today’s competitive global marketplace, OEMs must have the right product available at the right time to avoid losing market share to more agile competitors. Factors such as higher inventory turns, shorter product life cycles, and increased expectations for agility make a flexible and scalable integrated supply chain essential for success. Federal Electronics’ supply chain and logistics services provide the necessary flexibility and scalability to meet these demands, ensuring that your products are delivered efficiently and cost-effectively.

Strategic Supplier Selection: Our supplier network includes rigorously vetted and qualified suppliers of custom fabricated components (such as sheet metal and precision machined parts) located both domestically and in a low-cost region.
Supplier Business Process Alignment: Suppliers are adept at supporting the unique challenges associated with highly complex, highly engineered, highly regulated products.
Component Lifecycle Management: Rapid response to component end-of-life notifications maintains a viable pipeline aligned with your demand signals. Updating component profiles in our ERP system with the latest lead-time data ensures that ordering policies remain accurate.
Direct Shipping: Stock and ship products directly to your sites as part of a forecast-driven Kanban program.
Staging Options: Stage products at our Cranston facility as finished products or subassemblies for integration.
Global Logistics: Experienced in shipping to customer locations worldwide.
Material Requirement Planning
For forecast-driven engagements, periodic ERP system updates based upon your demand and inventory position, coupled with scaling factors (if applicable) optimizes supply without creating excess, or risking shortages.
Resetting supply and demand on a daily basis with dampening controls to eliminate order stream maintenance signal noise, produces greater reliability and responsiveness within the supply chain.
Decisions based on fresh information, processed within 24 hours, and communicated through an automated supplier portal, shortens the communication cycle between receipt of demand signals and rightsizing the supply chain.
Resource and Constraint Management
Finite scheduling algorithms, driven by material availability and executed on a nightly basis, ensures that labor and machine time allocation aligns with customer priorities.
Our ERP Throughput module communicates material and resource contraints that pose a risk to production schedules within 24 hours of identification, ensuring that projects remain on time.
Capacity utilization analysis, conducted bi-weekly, promotes the proper staffing and allocation of both direct and indirect resources.
Protecting Your Information: We use the latest cybersecurity protocols to securely disseminate technical information throughout the supply chain.
Active Monitoring: Demonstrated expertise monitoring supply chain risks and opportunities for higher complexity, highly engineered products.
High-Risk Supplier Focus: Increased monitoring and management of directed, sole-source suppliers of critical parts.
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Manufacturing Services

Specialized Capabilities for Higher Complexity, Highly Regulated Products

Federal Electronics offers a vertically integrated model with expertise in a wide range of electronics manufacturing capabilities. Our services are designed to address the unique challenges associated with multi-layered, highly engineered, complex systems and allows for rapid response to dynamic schedule changes. Higher labor content assemblies can be made in our Mexico facility either as finished products or as sub-assemblies for further integration at our US site.

Multi-level Bills of Material typically consisting of interconnect, PCBA, electronic controller and electro-mechanical sub-assemblies
Vertical integration model increases level of control over supply chain and assembly processes while eliminating margin stack up
Nightly MRP and Schedule modules capture changes in supply and demand throughout the multi-level configuration, ensuring changes in material and labor requirements are communicated within 24 hours
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US and Mexico sites both certified to UL 508a
Supply chain includes qualified, build-to-print enclosure manufacturers conveniently located in-region to both facilities
Process engineering converts point-to-point wiring from schematics and wire run lists to cable and harness assemblies, reducing costs and improving yields
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Vertical integration model increases level of control over supply chain and assembly processes, especially for PCBAs and interconnect assemblies frequently found within controllers
Functional testing conducted at both the sub-assembly and finished product level
Controllers can be shipped directly to customer sites or included in higher level/frame level assemblies
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Extensive experience sourcing motors, encoders, fans, proximity sensors and other electro-mechanical components
Custom functional test units are developed to ensure components are working per specifications
Supply chain includes qualified, build-to-print sheet metal and enclosure manufacturers conveniently located in-region to both facilities
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Supply chain includes qualified, build-to-print precision machine shops adept at highly complex, tight tolerance parts
Processes and fixturization ensure precision assembly for mission critical applications
Assembly within Class 10,000 clean room available
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Mycronics platform selected for quick setups and changeover
Min/Max Board Size: 2.7”x2”/36”x24”
IPC-A-610 and J-Std-001 to Class 3
Real-time operational visibility through Aegis FactoryLogix
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Artos and Schleuniger automated wire processing equipment reduces costs, increases throughput and optimizes quality
Conveyorized systems modified for higher complexity, highly engineered products
Harnesses containing over 2000 connection points
Cable assemblies over 130’ in length
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Connector styles include ST, SC, LC, etc.
Plastic and glass fiber
Individual interconnects or incorporated into higher level assemblies, including hybrid harnesses
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Sustaining Services

Support Throughout Your Product’s Entire Lifecycle

Aftermarket support is often unpredictable and difficult to forecast. Federal Electronics provides flexible and comprehensive services that extend the life of your products until your customers are ready to move on to the next generation.

Component and Material Support: Our engineering and supply chain functions coordinate with your team to extend the life of your products by managing component obsolescence and end-of-life notifications.
Robust RMA Process: Upon receipt of fielded products, our team will test, evaluate, and generate repair, refurbishment, or scrap options as appropriate, including conducting upgrades from down-level assemblies and subassemblies.
Repair Services: Our vertical integration model promotes repair or replacement of parts down to the component level.
Critical Parts Harvesting: For those products that are beyond repair or refurbishment, recovery and salvaging of critical parts, especially those that are now obsolete or end-of-life, becomes a critical component of a lifecycle extension policy.
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Partner with Federal Electronics

Contact us today to learn more about our solutions that are designed to drive your success.

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