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Unlocking High-Volume Productivity for a Global Commercial LED Manufacturer
Background
The Need to Drive Higher Production Output
A global commercial LED manufacturer (“the Customer”) needed to increase output of its top-selling, highest-volume LED fixture.
Production was constrained by a fully utilized cell where manual wiring, repeated electrical testing, and complex handling created a major throughput bottleneck.
What Did We Solve?
The Customer’s goal was clear: simplify assembly, reduce component handling, and boost productivity without new equipment.
They turned to Flex-Tec for a design- driven, cost-saving solution.
Our Approach
A Design Innovation Built for Speed
Flex-Tec partnered on the production floor and introduced the “Speed Module” — a fully tested, plug-and-play harness. Key improvements:
- Eliminated wiring bottlenecks with a plug-and-play module.
- Delivered fully tested components for consistent, ready-to-install performance.
- Removed in-cell electrical testing, reducing operator load and simplifying PFMEA.
- Enabled simultaneous driver-wire assembly, cutting handling time and improving ergonomics.
- Streamlined takt time with a faster, simplified assembly sequence.
Breakthrough Impact
3x Higher Throughput,
Zero CapEx
Flex-Tec’s engineered “Speed Module” transformed cell performance, enabling the Customer to achieve:
+3x Units/hr
3x increase in units per hour
-50% Labor
50% reduction in direct labor
0 CapEx
All gains delivered with zero CapEx
Sustainability
Improved ergonomics, quality, and reduced carbon footprint
Standardization
Standardized components handled within the cell
Takt-time
Major takt-time reduction
Why Flex-Tec Won
A Repeatable, Scalable Productivity Engine
Flex-Tec delivered differentiated strengths:
Collaborative, on-site engagement
DFM and modular design expertise
Quality at the source with fully tested harnesses
Scalable, repeatable and sustainable solutions across lines and regions
Rapid prototyping, validation and standardization