Series production of an irrigation controller
Series build of a field irrigation controller for an agtech company, from small NPI lots to steady batches with 100% functional test.
- Delivery geography
- Spain & Türkiye
- Annual volume
- ~5,500 units/year
- Batch size
- 400–800 per release
- Variants in scope
- 3 variants
- Program duration
- Second program year
- Responsibility level
- Series
- Standards applied
- IPC-A-610 Class 2 as practice · CE declared by the customer
What the delivered system actually does.
A field irrigation controller is a small computer that lives outdoors. It opens and closes valves on a schedule or on sensor readings, it has to survive sun, dust and water, and it fails in the one place where nobody is watching it.
GANI produces it in series for an agtech company, starting with small NPI lots — where the process, the fixtures and the work instructions are settled — and growing into steady batches once the build is stable.
Every unit gets a functional test, one hundred per cent. For a product distributed across fields rather than installed in one plant, a warranty failure costs a site visit that dwarfs the unit price, so testing every unit is the cheaper option by a wide margin.
An agtech company had proven its irrigation controller in pilot fields with hand-built units, but each one took hours to assemble and no two were quite alike. Scaling to distributor orders required a repeatable build, a test gate and a supply chain that survives component shortages.
STARTING CONDITIONA small-batch design existed with pilot-field history; assembly instructions lived mostly in the founding engineer’s head.
- Design files, BOM and a set of pilot units
- Field failure notes from the pilot season
- Distributor order pipeline and seasonal demand curve
- Enclosure and ingress protection requirements
- DFM pass converting the pilot build into documented work instructions
- PCBA coordination and enclosure sourcing through qualified processes
- Supply chain setup with buffer stock for long-lead components
- Test fixture design and 100% functional testing
- Kitting and boxed delivery per distributor order
What the program delivers.
- NPI lots closed with agreed documentation updates
- Series batches delivered ahead of two consecutive irrigation seasons
- Serial-number traceability from lot to test record
- Last-time-buy executed on one obsolete component without a delivery gap
