MacroFab > Case Studies > MacroFab Streamlines Production for Keyless Security Brand

MacroFab Streamlines Production for Keyless Security Brand

Technology Category

Analytics & Modeling - Real Time Analytics
Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Buildings
Electronics

Applicable Functions

Facility Management
Product Research & Development

Use Cases

Additive Manufacturing
Rapid Prototyping

Services

Hardware Design & Engineering Services

About The Customer

The customer in this case study is a keyless security brand that provides devices for commercial real estate buildings, parking garages, multi-family residential complexes, and other spaces that would otherwise require entry via physical keys, cards, and badges. The company was acquired by a Fortune 500 company in late 2021, which turbocharged the startup’s ability to grow and reach new customers. Prior to partnering with MacroFab, the brand worked exclusively with a cost-effective Taiwanese contract manufacturer. However, the COVID-19 pandemic brought about challenges in the production process, leading the company to seek a more sustainable solution.

The Challenge

The keyless security brand, a provider of devices for commercial real estate buildings, parking garages, and multi-family residential complexes, was facing a major challenge in its production process. The company had been working with a cost-effective Taiwanese contract manufacturer, which was capable of handling production-level volumes. However, the onset of the COVID-19 pandemic brought about frequent engineering design changes, which required significant oversight from the facility. The 14-hour time zone difference between the client and the manufacturer made real-time collaboration difficult. Overseas flights to facilitate on-site collaboration were considered, but these would delay production times and increase manufacturing costs. Given the uncertainty brought on by the pandemic, it was clear that this arrangement would not be sustainable.

The Solution

The company turned to MacroFab, a North American manufacturer, to overcome these challenges. MacroFab's unique and streamlined approach to electronics manufacturing offered significant advantages. The company's engineering team could collaborate with MacroFab engineers in real-time on potential design changes, eliminating the need for expensive international trips. MacroFab's robust network provided the company with ultimate flexibility in committing volume at every stage of the electronics manufacturing lifecycle. A few designs needed updating before full-scale production could continue. MacroFab suggested the company perfect its designs first in U.S. facilities built for rapid prototyping. Once all stakeholders were confident in the new designs, MacroFab moved production to a more cost-effective facility in Mexico, offering a similar price structure to the Taiwanese facility, but without the engineering-design change anxiety and inflexibility.

Operational Impact

The partnership with MacroFab has brought about significant operational benefits for the keyless security brand. The company no longer has to deal with the time zone difference, language barriers, and long overseas trips to validate engineering-design changes. The path back to production-level volume after making design changes is much quicker, which is crucial now that the business is part of a larger Fortune 500 company. With its shortened iteration cycle, the keyless security brand can bring new products to market faster. Throughout the iteration process, the startup has access to MacroFab experts who understand the ins and outs of modern electronics manufacturing. The company also doesn’t have to worry about committing a certain amount of production volume to MacroFab, a common challenge that comes with working with many large overseas manufacturers.

Quantitative Benefit

MacroFab's manufacturing network now produces thousands of units of one SKU with the keyless security brand.
The company has plans for ramping up a second SKU.
The company has decreased its production risk significantly by moving volume to MacroFab’s network.