GANI / CONTRACT MANUFACTURING — CAPACITY EXTENSION
Capacity extension for a telecom access device
Parallel low-volume production of a network access device beside the OEM’s own line, grown step by step toward full outsourcing of the variant.
PROGRAM PROFILE
- Delivery geography
- Poland
- Annual volume
- ~3,200 units/year after full transfer
- Batch size
- 250–400 per call-off
- Variants in scope
- 2 variants
- Program duration
- 12 months, pilot to full transfer
- Responsibility level
- Capacity extension
- Standards applied
- IPC-A-610 Class 2 as practice · Customer test specification
THE CHALLENGE
A telecom OEM’s main plant was saturated by a flagship product, starving a lower-volume access device of line time and pushing out lead times. They wanted a second source that mirrors their process — same test coverage, same traceability — without disturbing the running line.
STARTING CONDITIONThe device was in stable series production at the OEM, with released documentation, test software and an existing fixture design.
CUSTOMER PROVIDED
- Released production documentation and test software
- Reference units and the existing fixture design
- Process audit criteria from the OEM quality team
- Monthly demand split between the two sites
GANI OWNED
- Replication of the assembly and test process at GANI
- Duplicate test fixture build validated against reference units
- Pilot lots run in parallel with the OEM line for comparison
- Ramp of monthly volume as pilot criteria were met
- Shared traceability reporting into the OEM quality system
OUTCOME
What the program delivers.
- Parallel production released after joint pilot-lot review
- Variant transferred to full outsourcing within the first year
- OEM line time freed for the flagship product
- Identical test coverage and records maintained across both sites
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