The Washer That Kept Coming Back (Noida/NCR → Nhava Sheva)

UL-Listed Build: whitegoods harness with 100% continuity & hi-pot; FPY 99.5%.

A European appliance brand had a headache: a tiny wiring fault that showed up only after installation. Returns were noisy, diagnostics slow, and launch windows tight.

We matched them with a harness maker in Noida/NCR used to export work. The factory handled tooling and crimping; we handled the plan—sample dates, continuity + hi-pot on 100% of pieces, and a simple label scheme so left-hand and right-hand harnesses never swapped. We also asked for UL-recognized wires/connectors (where specified) and booked a third-party pull-test.

The next lot sailed through: 100% continuity & hi-pot pass, first-pass yield ~99.5%, deliveries on time, and returns went quiet.
Our role: shortlist, calendar, QC/lab booking, evidence packs. Factory role: build to spec and keep it consistent.

The EV Leads That Failed the Tug (Pune/Nashik → Nhava Sheva)

EV/Industrial leads: crimp pull-test & traceability (labeling/batch control).

An EV start-up set a pull-test target of ≥60N, but some terminations let go near 45N—and a few mixed labels crept into shipments.

We paired them with a Pune/Nashik supplier comfortable with EV harnesses. The factory swapped applicators and tuned the process; we set the “golden harness board,” locked a barcode label scheme, and scheduled independent pull-tests at the start of each lot. Every week the buyer got a green/amber/red dashboard and photos.

Within two cycles, all samples pulled ≥60N, zero hi-pot fails across 10k units, no label mix-ups, and OTD ~96%.
Our role: supplier match, traceability setup, test cadence, weekly reporting. Factory role: process tuning and build.

The Control Panel That Took All Day to Debug (Pune → Nhava Sheva)

Box-Build: control panel assembly (IPC-620 compliance, jig testing).

A machinery OEM loved their panel design but hated the last hour of production—switch-on time felt like a treasure hunt.

We sourced a low-volume/high-mix assembler and coordinated the ramp: the factory built the panel; we organized jig testing (simple pass/fail for each circuit), created photo-based work instructions with the team, and booked pre-shipment inspections that included labeling and packing checks. The buyer had a single tracker for samples, checks, and ship dates.Result: pass-at-first-power ~98%, debug time −40%, and on-time delivery up by ~20 points. Support tickets dropped with them.
Our role: supplier shortlist, jig/test plan, PSI & photo evidence. Factory role: assembly and wiring to spec (IPC/WHMA-A-620 workmanship).