A recent client needed a power supply product that could stream clean, uninterrupted power to mobile phone base stations. These phone base stations were installed in areas where power was often unreliable, experiencing surges, fluctuations, and noise that could severely disrupt the proper functioning of the base unit and cause disruptions to the mobile network or damage to the base stations. Since providing a stable mobile network for base stations was key to the brand’s reputation, we had to ensure that every phone base station power supply product the client received would provide steady power with the right current and voltage. As a turnkey manufacturing partner, we took responsibility for the design, suitability, and overall performance of the product, including developing the testing process necessary to validate the product against the client’s specifications.

Challenges

Our test engineering team analyzed the product features. It developed a plan to test high volumes of the phone base station power supplies within the production environment, working with the client to ensure a high quality was achieved and key objectives were met. The key to supplying high-volume, high-quality projects is extensive testing. However, with thousands of units being shipped each month for base stations, testing each one individually by hand would be impossible, and testing random selections wouldn’t produce the necessary quality level for every product shipped. The solution involved creating a test rack that could test as many as a thousand products at a time, checking every parameter they produced against pre-approved targets, and generating an error for any failed products.

By taking on the burden of developing the complete test plan and using it to deliver reliable phone base station power supplies, the client focused on product development and other core parts of their business better. Often this extensive level of testing is performed at the client’s end, meaning they’d have had to set engineering resources aside to design their own testing setup, costing them both time and money. We employ a team of test engineers who specialize in creating industrial-scale test racks and the software necessary to automate the testing, allowing the process to be done quicker and more efficiently.

Solutions

The client received high-quality phone base station power supply products that delivered the correct power levels to the mobile base stations, increasing network stability. Because we tested the products in-house, the time to market was reduced, and the project was scaled easily, with peak product delivery reaching 1M units received by the client in a single month. The client introduced their phone base station power supplies to the market quicker and offered a superior solution to the telecom network and service providers, boosting their business and helping them increase their market share. As the business relationship expanded, cooperation between our engineers and those of the client increased. We were asked to develop a test setup for the client to help their engineer debug issues found during the product development cycle. By the end of the project, we had become an invaluable partner and a key part of the client’s strategy.

Successes

We contribute our 40 years of design and manufacturing expertise spanning multiple diverse markets. We look forward to discussing how we can deliver world-class products for OEMs across the globe. We understand our home Indian market, familiar with its vast regulatory and selling environments. We foster growth opportunities within India through our strong technology incubation ecosystem. We also assist global OEMs in entering the Indian market by leveraging the local supply chain and favorable operating environments for cost reductions.

Our flagship Chennai location opened in 2006 and lies within a Special Economic Zone (SEZ) for electronics manufacturing, offering economic incentives for imports and exports. This primary facility is within 90 minutes of the Chennai seaport and 20 minutes to the international airport. Additional road and rail connectivity links to the rest of India and beyond and infrastructure advantages with faster import and export clearances. We also have labor force flexibility, both technical and manual, to scale to demand rapidly.

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