Today’s blog is in a different format, instead of talking about manufacturing and Quality Control principles, we’ll be going through a case study of a recent customer whom we supported: Metronome Technology with their Smart Energy Monitoring System!
Metronome Technology is an energy intelligence company aimed squarely at paving the future for a renewable future. They have a hardware and software solution that allows customers to monitor their cold storage facilities in real-time whilst analysing the costs of electricity alongside any local renewable energy generation.
Using Metronome’s technology enables farms to save up to 30% on their electricity costs by selectively turning on and off entire cold storage systems; whilst ensuring their product does not spoil by staying within a strict temperature and atmospheric margins.
Farms with a large cold storage facility can use up to £1M worth of electricity every year, so any amount of saving greatly helps their customers. Metronome couples this with prioritising electricity produced by renewable methods, ensuring farms have a greener footprint.
Objective - Mass Produce a Smart Energy Monitoring System
Ardencraft Technology was tasked to turn their prototype hardware module into a mass-producible product.
We worked with Metronome Energy to create a scope, project plan and then carried out the following:
In-depth Engineering Design Review (EDR) of their existing prototype.
Re-designed the PCBA to include more cost-efficient ICs and transformers.
Replaced PCBA components with local Chinese brands including
Transformers
ATmega Chip
Power IC Controllers
Inductors and Transistors
Sourced all PCBA components and plastic moulding parts within China.
Sourced several final assembly factories in China.
Created a full Quality Control strategy that was adopted by the factory through regular on-site Quality Control inspections and training.
Validated the product using best practices through Engineering Validation Testing (EVT), Design Validation Testing (DVT) and Production Validation Testing (PVT).
Carried out CE & RoHS Certification - ensuring it is safe to use for high voltages applications and LTE/4G applications.
Set up a Manufacturing Supplier Agreement between Metronome Energy, Ardencraft Technology and the China factory.
Key challenges identified with the project:
High Voltage Transformer requiring strong safety requirements
Facilitating a small Batch “Trial” order with large factories
Strict Wifi / 5G signal requirements to certify the product
The product is installed into the main electricity grid of Cold Storage facilities in farms; the electronic design was critical to ensure the safety of Metronome’s customers; high-voltage equipment need additional safety mechanisms to ensure that if something goes wrong, the user is protected at all times.
The tight safety requirements also prioritised critical components having rigorous Incoming Quality Control (IQC) and During Production Inspection (DPI) to ensure products were precise to the specification and do not deviate more than 0% - 1%: depending on the component.
Final outcome of the project:
Mass production price reduction of 35% from £180 to £110 per unit by replacing UK ICs with the equivalent (or better) native Chinese ICs.
Sourced several final assembly factories as well as all PCBA components and plastic moulding parts in China.
Established a new supply chain within China - enabling their products to be mass-produced at a reasonable cost, competitive MOQ and a 2 month delivery lead time.
Developed a full Quality Control strategy that was adopted by the factory.
CE & Safety certified the product so it can be sold in the EU.
Created a mass-production quote for 2000, 5000 and 10,000 units.
Overall the project was a huge success! We had successfully re-designed their product, reduced the price significantly and set up a regular production source for Metronome Energy.
“ Ardencraft Technology made the whole process so simple! Originally we weren’t sure which route to take and whether we could source from China directly ourselves; we didn’t have room for mistakes, so having experts in the field in China made a huge difference. We thoroughly enjoyed working with the team and Abid ensured everything was well planned and communicated to us “ - Daryl Rodrigo, CTO of Metronome
If you’re looking to develop your products or think part of your supply chain would benefit from a fresh perspective, please feel free to get in touch. Ardencraft Technology is a team of industry experts with decades of experience each and can solve a wide range of complex problems - whether it’s in Engineering Design, Manufacturing or Quality Control.
Feel free to get in touch at abid.ali@ardencraft.com
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