Contract Engineering provides essential services to aid product launch and innovation.
Our expertise can be customized to meet your need.
Electronic ControlsRefrigerationHarness
Overview
A Supply Chain that includes Contract Engineering services gets stronger from conception to production. InSource includes contract engineering support in Electronics, Refrigeration, and Wire Harness, which keeps the focus on deadlines, parts availability, and design for manufacturing.
Planning
Contract Engineering
| Planning | |
|---|---|
| Requirements Planning | You know the market. We know design. You give us the feature set, target cost, and timing. We give you feedback, candor, and results. |
| Conceptual Brainstorming | Tap into our broad experience for custom design approaches and new ideas. We offer a fast introduction to the market with a capable product. |
| Specification Development | Specifications are broadly defined in the beginning and detail is added just in time. This preserves flexibility throughout the design process. |
| Phased Scheduling | The highest value features are created first. You decide when sufficient features exist to make a viable product that can be upgraded later. |
| Ongoing Communication | We will communicate throughout the process to prioritize features, create details, and track schedule performance. |
Hardware
| Hardware | |
|---|---|
| Digital and Analog Design | Our electrical engineers have proven experience with a large variety of components and circuits. |
| Schematic Capture | We use PADS to allow collaboration with other designers. We have streamlined procedures to export to manufacturing. |
| PCB Layout | Our designs maximize performance and minimize defects. Our in-house production feedback loop creates continuous improvement. |
| Wire Harness | We design and produce wire harnesses with specialties in laser etched connector marking, braided loom, overmolding, and testing. |
| Enclosure Design | With 3D design tools, we can create custom molded plastic or we can CNC rout standard enclosures. |
| Focus on Cost | You will benefit from our knowledge of volume component costs, process times, and assembly methods. |
Software
| Software | |
|---|---|
| Agile Development Process | Our programming team works together to specify, code, test, and document entire features before moving on to lower priority features. This ensures that you get a functional, tested product, with must-have features quickly. |
| Embedded C Microcontroller Software | We have written code for 8, 16, and 32 bit projects for Atmel, TI, Motorola, and Microchip. We specialize in Microchip design due to cost and availability. |
| Communication Protocols: CAN, USB, WIFI, etc. | Interconnections are extremely important when focusing on modular designs. We have significant experience with protocol design. |
| Field Updateable Boot-loaders | We have written update mechanisms from USB, SD card, serial, CAN, WIFI, SPI, and I2C. |
| Supporting PC Applications | We often create PC applications to interface with the product being designed. They range from simulation software to software update tools to automated test applications. |
Validation
| Validation | |
|---|---|
| Quick Turn Electronic Prototypes | Quantity range: 1 to more than 100. Lead time: 1 – 3 weeks – the entire process includes bare board production, surface mount assembly, and through-hole soldering. |
| Verification and Validation | Testing plans are created and executed throughout the design process as features are created. Tests are automated to simulate a wide variety of conditions. Results are documented and used to improve the design before release. |
| Agency Approvals | We interface with test labs when seeking UL, CE, FCC, and other agency approvals. |
| FMEA and DFM Reviews | Our knowledgeable manufacturing engineers and production supervisors review new designs for potential defects and costly labor steps. |
| Beta / Pilot Production | We can move easily from prototypes into production with in-house circuit board and wire harness capabilities. |
| Manufacturing Test Design | We love to share our experience developing automated testers. A good manufacturing test will be independent of operator judgement, exercise all circuits, and report specific defects. |
Production
| Production | |
|---|---|
| Surface Mount Assembly | Our systems control production bills of materials (BOMs), verify reel setup, and automatically inspect each component (AOI) |
| Through-Hole and Robotic Soldering | Surface mount components are used wherever possible. Most other components are compatible with our robotic soldering equipment. Hand soldering is used for direct wire and cable attachment. |
| Wire Harness Fabrication | We have automatic wire processing lines that measure quality on every crimp. Each harness is tested for continuity, shorts, and inline component polarity. |
| Final Assembly and Testing | Whether assembled into a plastic enclosure or potted into a box, every device is tested at least once. We have a custom defect tracking system to provide feedback for design and process improvements. |
| Manufacturing Documentation | We are the connoisseurs of our own design documentation. Efforts are made to be complete, clear, and concise. |
Support
| Support | |
|---|---|
| Design and Process Improvements | Most surface mount defects can be eliminated through correct copper pad and stencil aperture sizing. Products are routinely reviewed for opportunities to remove defects, assembly time, or component cost. |
| Solutions for Unavailable Components | Every effort is made to create designs with components that will be available throughout the product life cycle. If parts become obsolete or scarce, we are prepared to find alternates or change the design to eliminate the bottleneck. |
| Warranty | We offer warranty and refurbishment programs based on contract negotiations. |
| Service and Repair | For products that are out of warranty, we offer cost effective solutions for service and repair. |
| Field Failure Analysis | Data is collected on root cause of failures returned in or out of warranty. Lessons learned are incorporated in later revisions and new products. |
Planning
| Planning | |
|---|---|
| Requirements Planning | You know the market. We know design. You give us the feature set, target cost, and timing. We give you feedback, candor, and results. |
| Conceptual Brainstorming | Tap into our broad experience for custom design approaches and new ideas. We offer a fast introduction to the market with a capable product. |
| Specification Development | Specifications are broadly defined in the beginning and detail is added just in time. This preserves flexibility throughout the design process. |
| Phased Scheduling | The highest value features are created first. You decide when sufficient features exist to make a viable product that can be upgraded later. |
| Ongoing Communication | We will communicate throughout the process to prioritize features, create details, and track schedule performance. |
Component Selection
| Component Selection | |
|---|---|
| Compressor | InSource uses Cubigel compressors and will use our resources to select the proper one for your application. |
| Coils | Our coil manufacturer supports our efforts to make sure that your system works. |
| Valve, Filter/drier, Receiver | We can help determine which components are needed in your design. |
| Wire Harness or Power Cord | We design and produce wire harnesses and power cords. |
| Sheet Metal Design | We can customize your base plate and fan bracket if volumes support it. |
| Focus on Cost | You will benefit from our knowledge of volume component costs, process times, and assembly methods. |
Prototype
| Prototype | |
|---|---|
| Quick Turn Prototypes | Quantity range: 1 to more than 100. Lead time: 1 – 3 weeks – depends on availability of parts |
| Verification and Validation | After the system is built, we can ship it to you for testing or complete testing here in our environmental chamber. |
| Agency Approvals | We interface with test labs when seeking UL, and other agency approvals. |
| FMEA and DFM Reviews | Our knowledgeable manufacturing engineers and production supervisors review new designs for potential defects and costly labor steps. |
| Beta / Pilot Production | We can move easily from prototypes into production with in-house copper tube fabrication, wire harness production and complete evacuation and charging lines |
Production
| Production | |
|---|---|
| Copper Tube Fabrication | We cut, bend, end form copper tubing from 1/8″ cap tube to 2″ water pipe. |
| Brazing | Our AWS certified employees braze brass, copper, and steel. |
| Wire Harness Fabrication | We have automatic wire processing lines that measure quality on every crimp. Each harness is tested for continuity, shorts, and inline component polarity. |
| Final Assembly and Testing | Each system is tested for leaks and charged. R134a, R410a, R404a, or Nitrogen depending on your specifications. |
| Manufacturing Documentation | We are the connoisseurs of our own design documentation. Efforts are made to be complete, clear, and concise. |
Support
| Support | |
|---|---|
| Design and Process Improvements | We focus on continuous improvement with every build. Products are routinely reviewed for opportunities to remove defects, assembly time, or component cost. |
| Solutions for Unavailable Components | Every effort is made to create designs with components that will be available throughout the product life cycle. If parts become obsolete or scarce, we are prepared to find alternates or change the design to eliminate the bottleneck. |
| Warranty | We offer warranty and refurbishment programs based on contract negotiations. |
| Service and Repair | For products that are out of warranty, we offer cost effective solutions for service and repair. |
| Field Failure Analysis | Data is collected on root cause of failures returned in or out of warranty. Lessons learned are incorporated in later revisions and new products. |
Planning
| Planning | |
|---|---|
| Requirements Planning | You know the market. We know design. You give us the feature set, target cost, and timing. We give you feedback, candor, and results. |
| Conceptual Brainstorming | Tap into our broad experience for custom design approaches and new ideas. We offer a fast introduction to the market with a capable product. |
| Specification Development | Specifications are broadly defined in the beginning and detail is added just in time. This preserves flexibility throughout the design process. |
| Ongoing Communication | We will communicate throughout the process to prioritize features, create details, and track schedule performance. |
Component Selection
| Component Selection | |
|---|---|
| Wire | We stock a large selection from 28 AWG wire to 4/0 battery cable to multi conductor cable and access to much more. |
| Terminals | We have applicators for AMP/Tyco, Deutsch, Molex, Packard, Panduit and many more. |
| Looming | Nylon braiding or corrugated loom, we got your wire covered. |
| Over molded ends | We design tooling and produce plastic injected over molding that cover many standard connectors. |
| Potting | We can weatherproof your custom cavity with various potting compounds. |
| Focus on Cost | You will benefit from our knowledge of volume component costs, process times, and assembly methods. |
Prototype
| Prototype | |
|---|---|
| Quick Turn Prototypes | Quantity range: 1 to more than 100. Lead time: 1 – 3 weeks – depends on availability of parts |
| Agency Approvals | UL certified wire harness manufacturer for ZPFW2 and ZPFW8. |
| FMEA and DFM Reviews | Our knowledgeable manufacturing engineers and production supervisors review new designs for potential defects and costly labor steps. |
| Beta / Pilot Production | We can move easily from prototypes into production. |
Production
| Production | |
|---|---|
| Cut, Mark, Strip | We cut, mark, strip and terminate in one operation. With multiple color options, we can mark on any color wire. |
| Routing | InSource has developed a peg board system instead of bed of nails so that we can switch over a line very quickly. |
| Splicing | Ultra sonic splicing eliminates butt connectors and piggytails when multiple wires go into one connector or ground plane. This method is recognized by UL when covered by heat shrink |
| Laser etching | We can laser etch directly to a plastic or metal to eliminate costly and time consuming labels that don’t stay on the connector anyways. |
| Final Assembly and Testing | We have testing equipment that measure quality on every crimp. Each harness is tested for continuity, shorts, and inline component polarity. |
| Manufacturing Documentation | We are the connoisseurs of our own design documentation. Efforts are made to be complete, clear, and concise. |
Support
| Support | |
|---|---|
| Design and Process Improvements | We focus on continuous improvement with every build. Products are routinely reviewed for opportunities to remove defects, assembly time, or component cost. |
| Field Failure Analysis | Data is collected on root cause of failures returned in or out of warranty. Lessons learned are incorporated in later revisions and new products. |