Complex printed circuit board assembly in a precision manufacturing environment

Service 01

Manufacturing & Operations Consulting

From EVT to Mass Production — 30+ Years of Hardware NPI Leadership

Contract manufacturer selection, failure analysis, quality systems, and supply chain optimization for hardware companies across consumer electronics, datacenters, aerospace, and AI hardware.

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Overview

What I Do

I help hardware companies navigate the complex journey from prototype to mass production. With 30+ years of experience leading NPI programs across three continents, I've seen every failure mode, supply chain bottleneck, and quality issue you can imagine — and I've developed systematic approaches to avoid or resolve them.

My consulting focuses on four core areas: contract manufacturer selection and qualification in Asia, NPI leadership from EVT through mass production, failure analysis and root cause investigation, and quality systems/supply chain optimization. Whether you're a startup building your first product or an established company scaling AI hardware across multiple CMs, I can help you de-risk execution and accelerate time to market.

Capabilities

Core Consulting Services

CM Selection & Qualification in Asia

I help you identify, evaluate, and qualify contract manufacturers in Taiwan, China, and Thailand. This includes:

Factory audits and capability assessments
RFQ process management and supplier comparisons
Quality system evaluations (ISO 9001, IATF 16949, AS9100)
On-site audits and production line reviews
Negotiation support and contract terms
Transition planning and knowledge transfer

NPI Leadership (EVT → Mass Production)

I lead your New Product Introduction from Engineering Validation Test through Design Validation Test, Production Validation Test, and mass production ramp. This includes:

NPI roadmap development and milestone planning
Cross-functional team coordination (EE, ME, SW, QA, Supply Chain)
Design for manufacturability (DFM) and design for assembly (DFA) reviews
Test strategy and production test equipment planning
Yield improvement and cost reduction initiatives
Concurrent program management across multiple CMs and continents

Failure Analysis & Root Cause Investigation

I build and operate failure analysis labs and lead root cause investigations for complex hardware failures. This includes:

Probe station analysis for IC and PCBA debugging
SEM/EDX (Scanning Electron Microscopy / Energy Dispersive X-ray) for material analysis
Acoustic microscopy for bond wire and solder joint inspection
Cross-sectioning and metallographic analysis
Fault tree analysis and 8D report preparation
Supplier quality issue resolution and corrective action plans

Quality Systems & Supply Chain Optimization

I help you build or improve quality management systems and optimize your supply chain for cost, quality, and resilience. This includes:

QMS implementation (ISO 9001, AS9100, IATF 16949)
Supplier audit programs and scorecard development
Incoming quality control (IQC) and process quality control (PQC) systems
Supply chain cost reduction (component sourcing, alternate supplier qualification)
Risk mitigation (dual sourcing, inventory strategy, geopolitical risk assessment)
Continuous improvement programs (Six Sigma, Lean, Kaizen)

Experience

Industry Experience

Consumer Electronics
High-volume smartphone, tablet, wearable programs
Datacenters
Server racks, networking equipment, storage systems
Aerospace
Major satellite and launch vehicle electronics programs
AI Hardware
GPU racks, AI accelerators, high-performance computing systems

Program Locations

Puerto Rico

Engineering & program management base

Taiwan

CM qualification & NPI builds

China

High-volume production & supplier development

Thailand

Southeast Asia supplier management

USA

Aerospace & AI hardware program oversight

Pricing

Engagement Models

Hourly Consulting

$150–$300/hour

Best for: Specific technical questions, design reviews, supplier evaluations, failure analysis support

Video calls and email support
Document reviews (schematics, BOMs, test plans)
Supplier audit participation
Ad-hoc technical guidance

Project-Based Engagement

$5,000–$15,000 minimum

Best for: CM selection, NPI phase gates, failure analysis projects, QMS implementation

Defined scope and deliverables
Weekly status updates
On-site visits (if needed, travel billed separately)
Final report and recommendations

Monthly Retainer

$3,000–$8,000/month

Best for: Ongoing NPI leadership, supply chain oversight, fractional VP of Operations role

Dedicated time allocation (10–20 hours/week)
Priority support and rapid response
Regular team meetings and program reviews
Strategic planning and roadmap development

Let's Discuss Your Project

Whether you're selecting a CM in Asia, ramping a new product, or investigating a critical failure, I can help you de-risk execution and accelerate time to market.

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