Programs we've shipped.

Real programs across medical, industrial, and EV, with measurable outcomes.

Medical Devices

Medical Imaging Cable Assembly: 500 Units / Quarter

Redesigned and scaled a patient-side imaging cable assembly from a low-yield supplier to a stable 500-unit-per-quarter program with full traceability.

Challenge

Customer's incumbent supplier was returning >8% failure rates on hipot, blowing through schedule and triggering field returns. They needed a partner who could re-tool the build, hold tolerance, and ship documented lots on a quarterly cadence.

Solution

Re-engineered the strip-and-crimp profile, introduced crimp-force monitoring on the production line, and instituted 100% hipot test with serialized per-unit records. Built dedicated form-board tooling for repeatable routing.

Process

DFM review of the legacy drawing pack
First-article approval against agreed gauge & sample
Production cell stood up with crimp-force monitoring
100% hipot + continuity on every unit
Serialized records archived with each lot ship

Outcome

Hipot failure rate dropped from 8% to under 0.2%
On-time delivery at 100% for the last 6 quarters
Full lot traceability ready for FDA documentation
Customer consolidated 3 cable SKUs to VezeWire

Industrial Equipment

Industrial Automation Harness Kit: 12 SKUs

Consolidated 12 panel-harness SKUs into a kitted program that ships labeled, bagged, and ready to drop into the customer's panel-shop workflow.

Challenge

Machine-builder OEM was burning panel-shop hours on in-house wire prep. They needed harness kits pre-cut, pre-terminated, color-coded, and packed in the sequence their assemblers built panels.

Solution

Built 12 dedicated form boards, standardized wire selection to UL 508A-compliant MTW, and packed each kit in zip-top bags labeled by panel position. Shipped on a weekly cadence per blanket PO.

Process

Joint workshop to map shop-floor build sequence
12 SKU drawings & pull-sheets approved
Form boards built and first-articles approved
Weekly drop shipments per blanket PO

Outcome

Customer cut panel build time by 35%
Panel-shop scrap dropped to near zero
Single PO covers a quarter of kit demand
Program expanded to a second machine line

EV & Battery Systems

EV Prototype Development: 14-Day Turnaround

Built the full HV interconnect prototype set for an EV startup's first integration vehicle in 14 days, including DFM feedback that caught two routing conflicts.

Challenge

EV startup had a hard date for a closed-track demo. Their HV pack and inverter were finalized, but the interconnect harness drawings were rough and the budget didn't allow a redesign loop.

Solution

Engineering team scrubbed the drawing pack inside 48 hours, flagged two routing conflicts before any wire was cut, and hand-built the full prototype set with serialized labels and per-unit hipot records.

Process

Drawing intake and DFM review (48 hrs)
Routing conflicts flagged and resolved
Material kit sourced and inspected
Hand-build with photo documentation
Hi-Pot + continuity on every assembly

Outcome

Prototype set delivered in 14 days
Demo vehicle hit closed-track date
Customer awarded the pilot production program
Two design issues caught before metal was cut