Building World-Class EMS Operations & Scalable Manufacturing

A new entrant to the EMS sector needed end-to-end operations setup, core leadership team recruitment, equipment selection, customer audit qualifications, and immediate commercial ramp-up.

• Strategic planning & factory site selection (city, area, layout)
• World-class cleanroom & line layout for SMT & backend lines
• Equipment selection, benchmarking & turnkey vendor setup
• Leadership team hiring and foundational process creation
• ISO readiness, quality management system & certifications

Needed a fully operational assembly & testing facility for cutting-edge robotic automation systems, requiring robust industrial processes and executive leadership structure.

• Designed & set up a complete greenfield operations facility
• Defined functional standard processes for production, quality, ME & planning
• ERP system evaluation & SAP Business One (B1) implementation
• Hired and onboarded entire operations leadership team

Customer needed to expand into modern SMT manufacturing with optimal line configurations, cleanroom layout, and strict process setup for precision instrumentation.

• Product complexity analysis & technical RFQ release
• Equipment selection, benchmarking & vendor negotiations
• Layout design for SMT line and supporting backend processes
• Training on SMT fundamentals, reflow profiles & operations support

Expansion into high-volume SMT manufacturing with dedicated plant space, demanding right-sized line configuration, warehouse flow, and leadership structure.

• Product requirement definition and benchmarking with existing SMT lines
• Equipment selection & vendor negotiations for maximum capex efficiency
• Layout design for SMT line and overall new factory layout
• Hiring & onboarding of operations leadership team

Customer wanted to insource captive manufacturing of PCBA and complete box-build operations for complex products covering Automotive, Industrial, Defense, and Aerospace segments.

• Product complexity analysis and future product technology roadmap
• RFQ generation for advanced SMT and specialized post-SMT equipment
• Equipment benchmarking, selection & high-stakes vendor negotiations
• Comprehensive layout design for SMT line and overall new factory

Rapid manufacturing process setup and scaling up operations to win major enterprise client contracts against global competition.

• Evaluated and implemented MES for real-time tracking and control of shop floor
• Redesigned organization structure, sourcing, and hiring for key operations roles
• Hosted and defended critical customer audits resulting in business wins
• Capacity modelling & standardized operational workflows

Required rigorous operational benchmarking and yield enhancement across both SMT and high-power post-SMT assembly lines.

• Identified improvement areas vs world-class tier-1 EMS benchmarks
• Optimized SMT, MI, wave soldering & post-SMT assembly flows
• Improved shop-floor physical flow, line productivity & quality performance
• New factory architectural design and equipment selection

Needed operational benchmarking and deep technical improvements across SMT & post-SMT operations for high-density industrial control boards.

• Benchmarked SMT and Post-SMT operations against world-class practices
• Optimized SMT, Manual Insertion (MI), wave soldering & backend processes
• Streamlined shop-floor line balancing, operator ergonomics & quality controls
• Engineered scalable operations with confidence to deliver world-class products

Persistent SMT & Post-SMT process challenges, high wave soldering rework, and strict qualification barriers for tier-1 automotive clients.

• Benchmarked SMT & post-SMT operations against world-class standards
• Optimized SMT, MI, wave soldering, and post-SMT as per defense & automotive specs
• Improved wave soldering thermal profiles and long-term product reliability
• Built strong process controls for critical steps like conformal coating

Establishing scalable, bulletproof operations for an exceptionally fast-growing mobile phone manufacturing facility.

• Organization design for high-volume mobile manufacturing operations
• Evaluation, screening, and hiring for the operations leadership team
• Deep shop-floor evaluation across production, quality, IE & ME departments
• Comprehensive MIS implementation covering all shop-floor operations

Promoter group needed deep EMS industry expertise to evaluate, shortlist, and audit potential EMS targets for a strategic acquisition.

• Reduced target pool to 3 strategic EMS partners and finalized single best opportunity
• Conducted operational audits & capability assessment of each prospect
• Business assessment, inventory valuation, and physical machine asset verification
• Designed 90-day post-merger integration plan for processes, capacity & risk mitigation

Sponsor required comprehensive technical infrastructure assessment, operational risk mitigation, and enterprise scaling architecture to evaluate specialized design-led EMS capabilities for a strategic acquisition in defense and aerospace electronics.

• Evaluated specialized design-led manufacturing capabilities and executed holistic business assessment
• Outlined a multi-phase operational expansion plan, encompassing equipment modernization and technical infrastructure upgrades
• Strategic Human Capital Architecture & Quantitative Projections for mission-critical leadership and engineering cadre onboarding post-acquisition

As part of continuous process improvements on high-density SMT manufacturing lines, client required comprehensive SMT process setup, line optimization, and benchmarking against world-class standards.

• Detailed SMT process setup and optimization across solder paste printing, SPI, high-speed & fine-pitch placement, and reflow profiling
• Comprehensive benchmarking and continuous process improvements of shop-floor SMT operations as per world-class EMS standards

Luminous required a comprehensive, high-impact operational and process audit across its high-volume inverter manufacturing facility in Baddi, targeting zero-defect PCBA production and world-class manufacturing compliance.

• End-to-end operational audit covering Material Receiving, Incoming Quality Inspection (IQC), and warehouse storage conditions
• Comprehensive evaluation of SMT line parameters, solder paste printing accuracy, and reflow thermal profiling for power electronics PCBA

Customer needed operations benchmarked and systematically optimized across high-precision SMT & post-SMT manufacturing lines for computing and electronics solutions.

• Benchmarked SMT and Post-SMT operations against world-class manufacturing practices
• Optimized SMT, Manual Insertion (MI), wave soldering & backend processes
• Streamlined shop-floor flow, productivity, line balancing & quality controls
• Engineered scalable operations with confidence to deliver world-class products

Establishment of captive manufacturing operations for smart energy meters, demanding advanced SMT line engineering, technology supplier evaluation, and comprehensive factory layout design.

• New SMT Line design tailored specifically for smart energy meter PCBA and high-volume electronics
• Supplier selection and benchmarking based on technical requirements and equipment offerings
• Comprehensive cleanroom and factory layout design for captive manufacturing of smart energy meters
• Turnkey integration of SMT placement, testing protocols, and backend assembly flow

Electrohms required comprehensive technical process qualification and manufacturing audits of an existing EMS supplier producing mission-critical electronics, demanding strict compliance with high-reliability industrial standards.

• Comprehensive process qualification audit of the existing EMS partner
• In-depth shop-floor audit across SMT assembly, selective & wave soldering, and IPC workmanship criteria
• Root cause failure analysis, quality gap identification, and corrective action verification
• Standardized process control gates, ESD protection, and qualification framework for high-reliability production