Overcoming the components shortage with agile manufacturing capabilities
Exeter-based engineering company reengineers its portable sensor display in-house, keeping it on the market amidst the global components shortage
Sensing and measurement specialist Mantracourt has reengineered its PSD-232 portable sensor display, which serves sensor manufacturers, like load cell manufacturers and integrators, using its in-house manufacturing and testing capabilities and readily available components. The redesign was needed when the processor used in the original design was deprioritised for production by the manufacturer and the price on available units increased from $5 per unit to $160 per unit. Mantracourt’s agile manufacturing capabilities allowed its engineers to overcome design challenges around component size and I/O availability, producing a final product with features broadly similar to the original PSD-232.
Mantracourt’s handheld PSD-232 device is used to collect information from strain gauges and load cell sensors, measuring forces such as tension and compression. It can also be used to measure variables like pressure and torque in other sensor types. While producing the PSD-232 unit has traditionally been a routine part of Mantracourt’s operations, recent disruptions to global market conditions and supply chains meant that the product could no longer be made cost-effectively in the usual way.
The company that makes the processor used in the original product was bought out and has since deprioritised manufacturing it. While it is still supplied, lead times were consistently above 52 weeks and often as high as 74 weeks. Furthermore, the processor price drastically increased from $5 to $160, meaning the PSD-232 could no longer be produced reliably or cost-effectively.
To overcome this challenge, Mantracourt set about reengineering the product by using available components and taking advantage of its in-house manufacturing design and testing capabilities. This presented challenges as the new processor limited I/O availability compared to the previous version, meaning it could not support the TEDs facility. However, this was not an essential feature for most customers, so this could be sacrificed to ensure reliable delivery of the device’s primary functions.
Furthermore, there were some issues around component spacing and difficulty placing the tracks as there was less space available on the new design compared to the previous one. However, with consistent communication between the design and test teams, the product could be tested and refined several times until a suitable design was reached.
“Typically, when a product is engineered, a lot of time is wasted shipping it between the manufacturing design and testing facilities, which are normally separate, and that’s before accounting for the time where the product just sits on a shelf waiting. This process might then be repeated several times as the product is reworked,” explained Alistair Candler, production manager at Mantracourt. “Because Mantracourt has manufacturing and testing capabilities under one roof, the reengineered PSD-232 could be passed between the manufacturing and testing teams in minutes, minimising cost and project delivery time.
“Having the manufacturing and testing teams working so closely together meant that they could talk face-to-face immediately to make any modifications required and get scripts verified. This meant that a process that would normally take weeks, or even months, to complete could be done in a matter of hours. It is also beneficial in terms of meeting sustainability targets as there was no need to repeatedly transport the product between different facilities,” concluded Candler.
Mantracourt’s in-house agile manufacturing design and testing capabilities means customers can have confidence in its ability to maintain supply despite changes to global market conditions. To find out more about the handheld PSD-232, visit www.mantracourt.com/documents/PSD-232-portable-handheld-indicator.
