Contract Engineering - Embedded Engineering

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

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.