SOLUTION

Product Design & Development

A successful product requires a well thought-out design. At ESCATEC, we take your idea and transform it into a fully certified product, ready to manufacture at the lowest cost of ownership.

Transforming ideas into certified, ready-to-produce products

At ESCATEC, we specialise in taking your ideas and turning them into fully certified, ready-to-manufacture products. We understand the challenges OEMs face: tight deadlines, the pressure of client demands, and the difficulty in recruiting the right talent. These challenges can impede growth, but we know that growth is the key to profitability. Successful growth happens when operations are streamlined, when teams are focused, and when you have a partner who offers comprehensive design and manufacturing solutions.

What’s your biggest challenge?

  • Struggling to find skilled staff?
  • Falling behind on client projects?
  • Losing valuable engineering and design time?

At ESCATEC, we help you overcome these obstacles with a collaborative, trustworthy partnership that focuses on quality and efficiency at every step.

ESCATEC: your end-to-end partner

Whatever your specific challenge may be, ESCATEC has the expertise and capacity to support you across the entire product lifecycle—from initial concept through to obsolescence management. We ensure that your product will grow with your business while minimising risks and maximising long-term success.

Our engineers work closely with you to define your product’s architecture, tailoring each design to meet your specific requirements. What sets ESCATEC apart is our approach to design for manufacturability. We make this a priority early in the development process, which helps reduce costs, eliminate waste, and ensure a smooth transition from prototype to production, ultimately accelerating time-to-market.

ESCATEC end-to-end partner

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Why choose ESCATEC?

 

  • Proven Expertise: Since 1984, customers have trusted us to bring their visions to life.
  • Comprehensive Services: Whether it’s electronics hardware, software, or mechanical design, our in-house experts deliver high-quality solutions.
  • Focused on Your Success: We combine design and manufacturing expertise to create products that perform, innovate, and grow your business.

OUR DESIGN & DEVELOPMENT EXPERTISE

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Design for eXcellence

80% of cost is typically determined during product design. That’s why we begin early with DfX, encompassing all design and manufacturing processes. Your product is continuously optimised for performance and quality, improving time-to-market and your complete satisfaction.

DfX ensures:

  • Specified materials and components will always be available/replaceable
  • Manufacturing waste is minimised
  • Production errors are minimised
  • Products always meet required standards
  • Products can be tested easily and cost-effectively
DESIGN FOR PROCUREMENT

The success of any new product relies on effective selection of all components, materials, and suppliers. ESCATEC has Design for Procurement (DfP) expertise across electrical, electronic, mechanical, and electro-mechanical disciplines. And with highly experienced purchasing and engineering groups within Malaysia, Switzerland, Czech Republic, Bulgaria and the UK with access to a global network of suppliers, we are ideally placed to advise and support customers at the critical design stage.

Getting this right will have an important impact on the products viability throughout its lifecycle and provide significant benefits downstream, including:

  • Reduced time-to-market
  • Lower material lead-time
  • Minimised material liability
  • Consolidated suppliers
  • Extended product lifecycle
DESIGN FOR MANUFACTURE

Design for Manufacture (DFM), sometimes called Design for Manufacturability, is the element of the design effort that focusses on producibility to enable the product to be assembled in the most cost-effective manner, in a shorter time frame, with superior quality.

As most of the product lifecycle costs are committed at design stage, this is clearly a critical stage in the overall product design process. The concept of design for manufacture may be found across most engineering disciplines, but the specific details will clearly vary according to the manufacturing technologies being harnessed. Getting this right will have an important impact on the product’s viability throughout its lifecycle.

ESCATEC has considerable experience in working with customers at this critical stage to help to ensure that their designs are optimised for the manufacturing processes that will be used downstream and that all factors such as component specifications, dimensional tolerances and the required secondary processes are all considered.

This approach is applied equally to all manufacturing projects that ESCATEC undertake, i.e., PCB assemblies, box build assemblies, cable harnesses and looms, panel wiring, system integration and electro-mechanical builds.

Design for Manufacture has the potential to generate significant improvements, such as:

  • Enhanced manufacturing productivity
  • Improved product quality and reliability
  • Reduced/simplified maintenance
  • Reduced cost
  • Decreased time to market
  • Increased customer satisfaction
DESIGN FOR TEST

Design for Test (DFT) sometimes called Design for Testability is the element of the design effort that focusses on ensuring that the required level of testability features are incorporated into hardware product designs in order to make it easier to develop and apply manufacturing tests.

This is a critical process as PCB assemblies have become increasingly more complex and the ability to test these using traditional methods and systems has become more difficult. Therefore considering design for test in the early stages of product development is vitally important in order to ensure that adequate fault coverage and diagnostic ability is available. 

DFT delivers benefits including:

  • Increased test coverage
  • Reduced test times
  • Simpler test requirements
DESIGN FOR QUALITY

A Design for Quality (DfQ) strategy identifies potential product and process failure risks as early as possible to ensure they are ‘designed out’ of the product.  

A DfQ approach can prevent you from getting locked into compliant but not necessarily cost-effective designs.  If a design has proceeded to the prototype stage and been validated for regulatory compliance, you may be committed to manufacturing a product in a certain way for a lengthy period. It might not make sense to re-submit your design to regulators at that point - so your ROI and customer value could be severely impacted.  

At ESCATEC we take a holistic approach to DfQ so that the best value and quality outcomes for customers are always achieved.

DfQ ensures quality by:

  • Identifying potential quality risks through Design Failure Mode and Effects Analysis (DFMEA), ranking potential severity of failures and prioritising areas for action.
  • Ensuring products are designed so they can only be assembled one specific way, minimising potential non-conformities.
  • Simplifying the design to reduce costs and the risk of failure.
  • Standardising parts where possible so compliance is easier to establish.
  • Having a multi-functional team of experts to drive the process ensures the overall quality of the product is maintained within the design.
  • Ensuring required documentation is completed within the design process helps prove regulatory compliance - helping you achieve ISO 13485, ISO 9001, CE marking and FDA certification as required.  
  • Ensuring design processes are stage-gated to continually validate deliverables against engineering/customer/regulatory requirements. Stage gating your design process is a requirement of the medical device development standard ISO 13485:2016.
  • Ensuring required manufacturing processes are documented, validated, and engineers are appropriately trained to produce the product to the right standard.
DESIGN FOR ENVIRONMENT

Product designs can often have unintended environmental consequences, including:

  • High levels of waste through a lack of repairability. 
  • Damaging emissions during production.
  • Use of unsustainable materials. 
  • Potential to pollute after disposal. 
  • An unoptimised supply chain with a large carbon footprint. 

By bringing expert manufacturing teams into your design process you can ensure, from the outset, you are following best practice laid out in various environmental codes, including these standards and regulations:

Lean project management

When you partner with ESCATEC on a design project you will immediately benefit from our 40 strong engineering team based in Switzerland.

Our engineers are grouped into two highly competent teams with decades of experience between them. The first focuses on Design & Development while the second team focuses on NPI and product lifecycle management. The engagement and mix of engineers in any given programme are determined by the functional needs of the customer.

Effective project management is extremely important due to the technical services we offer. Project Managers are assigned based on their specific talents and experience; ranging from the development of complex medical devices according to ISO13485 standards to industrialisation of new products across a range of market segments.

lean project management

Typically our Project Managers concentrate on one project at a time, which can range from several weeks through to a year. This level of focus enables them to fully immerse themself in each assignment and thereby build trust and a strong relationship with the customer.

To be successful, Project Managers must possess critical leadership, planning, and communication skills, they also need to be able to inspire teamwork and commitment in multi-disciplinary team members, and be knowledgeable about risk minimisation strategies in order to strike an effective balance between all stakeholders i.e. the customer, suppliers, employees and management.

Project managers

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Optimising life-saving medical equipment for Carl Reiner GmBH

Seeking to optimise a mechanical ventilation system for throat surgery, Carl Reiner GmBH partnered with ESCATEC for an end-to-end solution. By integrating cutting-edge R&D, precision engineering, and rigorous safety protocols, ESCATEC designed and manufactured an advanced system, built to ISO 13485 standards, that delivers precise oxygenation and pressure control tailored to patient needs.

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Value analysis and value engineering

Optimising Products for Performance and Cost

At ESCATEC, we understand that in today’s competitive landscape, the key to successful product development lies not only in innovation but also in ensuring that your product is optimised for both performance and cost. Our value analysis (VA) and value engineering (VE) capabilities are designed to help you achieve this balance—delivering high-quality, cost-effective products without compromising on functionality, reliability, or time-to-market.

What is Value Analysis & Value Engineering?

  • Value Analysis (VA): This systematic approach focuses on identifying the functions of a product and finding the most cost-effective way to deliver those functions. By analysing each element, we eliminate unnecessary costs and enhance the overall value of the product.
  • Value Engineering (VE): VE builds on VA by applying a structured methodology during the design and development phases. It focuses on improving the product’s design, performance, and manufacturability while reducing production costs and time.

Together, VA and VE help your business maximise product value while reducing unnecessary complexity and expense.

Why choose ESCATEC for value analysis and value engineering?

At ESCATEC, we partner with you to achieve significant cost savings, higher quality, and improved product performance by applying our value analysis and engineering techniques at every stage of development—from initial concept through to production and beyond.

  • Collaboration from Day One: We work closely with your design and engineering teams to understand the core requirements of your product. Our goal is to align our efforts with yours, ensuring that every decision we make supports both performance and cost optimisation.

  • Holistic Product Evaluation: Through comprehensive assessments, we analyse all aspects of your product’s design, materials, components, and processes to identify opportunities for improvement. Whether it’s simplifying a complex design or recommending alternative materials, we focus on enhancing value across the board.

  • Cost-Effective Solutions: By eliminating non-value-adding elements and exploring alternative approaches, we help you reduce production costs without sacrificing quality or functionality. Our team ensures that every dollar spent brings maximum value to your product.

  • Improved Time-to-Market: With our deep understanding of manufacturing processes, we incorporate value engineering principles to streamline production. This helps reduce delays, avoid costly rework, and speed up time-to-market for your product.

  • Sustainability and Compliance: ESCATEC’s VA and VE strategies are not just about cutting costs—they also ensure that your products meet regulatory standards, maintain sustainability, and are ready for the long term.

Our value engineering process

Our approach to value engineering follows a structured, proven process that includes:


  • Function Analysis: Identifying and analysing the essential functions of your product.
  • Creative Design Solutions: Developing alternative approaches to meet functions more cost-effectively.
  • Evaluation and Optimisation: Assessing alternative designs and selecting the best options based on value and feasibility.
  • Implementation: Collaborating with your team to implement the optimised design and processes into production.

Benefits of Value Analysis & Value Engineering with ESCATEC


  • Cost Reduction: Drive down the total cost of ownership by optimising material choices, manufacturing processes, and design elements.
  • Enhanced Performance: Ensure your product not only meets but exceeds your performance expectations.
  • Risk Mitigation: Reduce the risk of delays, errors, and cost overruns through early identification of potential issues and design improvements.
  • Sustainability: Emphasise environmental considerations by selecting materials and manufacturing processes that reduce waste and improve energy efficiency.

At ESCATEC, our focus is always on delivering the best possible results for our clients. Our value analysis and value engineering capabilities are just one way we help you stay competitive in the marketplace. By optimising your product’s design and manufacturing processes, we help ensure that your products perform better, cost less, and reach the market faster.

RESOURCES

The OEMs Guide to
Implementing VA/VE

Explore the 6 steps of the classic value engineering process and how it can help your business maintain quality and drive new cost savings across your product suite.

Explore ESCATEC’s full range of services

ESCATEC's manufacturing capabilities are complemented by enhanced support services for our clients, such as design and development support, test solutions, sophisticated supply chain management, postponement manufacturing and direct-ship outbound logistics.

PCB Assembly

We support customers from the prototype and industrialisation stages, through to the ongoing manufacture of complex, multi-technology PCBAs, in low, medium and high volumes.

Box Build Assembly

We're experts in complex sub-assemblies and finished, tested, products. We offer turnkey electronics, mechatronics, cabinet assembly, system integration & test solutions.

Mechatronics

ESCATEC offers a wide range of mechatronics solutions and supply chain experience - everything from ‘benchtop’ products through to ‘large format’ electro-mechanical machines. 

Machining

From simple CNC turned components to elaborate CNC milled assemblies, we cater to diverse sectors, including industrial electronic, transportation and medical device manufacturing.

Test Solutions

A proven method of electronics manufacturing defect detection and prevention, flying probe testing also eliminates the requirement for dedicated fixturing.

Plastic Injection Moulding

At ESCATEC we use cutting-edge technology and equipment, to ensure that every injection moulding project we undertake meets the highest standards of quality and precision. 

Microelectronics

Our experienced teams design, develop and manufacture high performance LED, laser, and lighting solutions. We ensure micro-optic needs for complex MOEMS products are met and delivered.

Design & Development

Design & Development

We specialise in electronics, software, mechanical, and system design and development. Following Design for eXcellence (DfX), Design for Manufacture (DFM), and VA/VE best practices, we turn your ideas into market-ready products.

New Product Introduction

New Product Introduction

Our unmatched NPI support is characterised by lean project management, comprehensive testing, robust supply chain management, and close collaboration with your teams to minimise risks, maximise results, and ensure product quality.

Supply chain management

Supply Chain Management

With our established global supplier partnerships, our experienced procurement, SCM, and logistics teams can identify the best sourcing options based on your needs. We supply a vast range of products to various sectors reliably and cost-effectively.

Prototyping

Prototyping

With our prototyping services, we are with you every step of the way, from schematic design to functional testing and validation. We work with you to refine your designs, creating a high-quality final product ready for mass production.

post production

Post-production

Whether you’re launching a new and improved product iteration or extending the lifecycle of your existing in-market products, our post-production capabilities help to maximise profits and keep you ahead of the competition.

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