Background
A leading domestic supplier of electronic controls and converter drive controllers for on-shore & offshore wind turbines, specialising in wind‑turbine main control drive units.
Challenge
- Cost & Supply Chain Pressures: Intensifying price competition in the wind power sector demands strict cost control. Meanwhile, supply volatility in power devices and specialty capacitors constantly threatens delivery stability.
- Industry-Wide Technical Bottleneck: The high copper thickness of their core boards poses a significant challenge. Conventional wave soldering fails to achieve the 100% barrel fill required by IPC Class 3+ standards, resulting in high rates of cold joints and poor wetting, leading to frequent prototype failures.
Norautron Solution
- Cross-Functional Agile Team: Deployed a dedicated wind power task force integrating Project Management, engineering, supply chain, and production experts to establish a rapid-response mechanism.
- Specialized Heavy Copper Soldering Process: Invested in advanced selective soldering equipment, paired with our senior engineering team. We successfully overcame the heavy copper soldering bottleneck, consistently achieving IPC Class 3 perfect barrel fill and eliminating the client’s core quality issue.
- Alternative Sourcing & BOM Optimization: Synchronized component risk assessment, parameter matching, process adaptation, and pilot-run validation. Once materials are Clear-to-Build (CTB), wind power prototypes are delivered within just 3 to 5 days.
- Unified Quality Control: Enforced rigorous, high-reliability manufacturing standards across the entire workflow, ensuring consistent quality across multiple SKUs.
Achievement
- Zero Defects & Rapid NPI: Completely eradicated heavy copper soldering defects. Prototypes now achieve first-pass success, drastically shortening the New Product Introduction (NPI) certification cycle.
- Supply Resilience & Cost Reduction: Multi-source alternatives and BOM optimization have effectively neutralized component shortage risks while significantly driving down overall material costs.
- Market Leadership Secured: Our flexible manufacturing lines are designed to support high-mix, low-volume (HMLV) production, helping customers accelerate new product development, implement cost-saving measures, and strengthen their competitive position in the wind energy sector.