FLEX

BACKGROUND

Introduce your business and what you do there.

My company is a radiation oncology manufacturer and we basically manufacture two different products. One is a robotic arm that delivers doses of radiation for cancer patients, and the other is a fully rotational radiation oncology device for tomotherapy. The third part of our company is service, which involves the actual maintenance and upkeep of these two product lines.

My role is VP of the global supply chain, so I’m responsible for all the components that go into it. Part of the supply chain is direct and indirect material, finished goods, and built-up components.

OPPORTUNITY / CHALLENGE

What challenge were you trying to address with FLEX?

FLEX is a very big and financially strong company, so the challenges we were trying to address were right-sizing the FLEX manufacturing footprint, and increasing the spending on components. They had a high volume of production while we were a mix of low and high volume, so we had a lot of different variables we were trying to figure out.

SOLUTION

What was the scope of their involvement?

The deliverables of FLEX were just simple and multilayered PCBAs (Printed Circuit Board Assembly) with a vibration control implementation. The printed circuit boards don’t really like to be vibrated, so we had to be very robust with the soldering and the quality of requirements around it.

What is the team composition?

The relationship was built around the sales aspect of it, so we had a regional manager and we also worked with the quality team all the way through engineering.

How did you come to work with FLEX?

FLEX is an industrial giant and they’re very well known. However, I came to know them best from my previous job. I was quoting out the whole electronic space, and FLEX was one of the companies that I brought to the table.

How much have you invested with them?

We probably invested around $26 million.    

What is the status of this engagement?

We worked together from January 2016–January 2018.

RESULTS & FEEDBACK

What evidence can you share that demonstrates the impact of the engagement? 

FLEX did a really good job of being able to leverage their spin and get results. The quality of the boards based on the metrics scored a 98% on the testing. We wanted 100% but whenever that happened, we just send the boards back so they can repair them. Flex also delivered on time and they were responsible for the inventory stocking requirements for the subcomponents.

How did FLEX perform from a project management standpoint?

Much of the relationship was built on the regional side, but with projects like these, they basically needed to have a lot of transparency across what the testing requirements and deliverables were. If they didn’t, the product won’t be successful.

What did you find most impressive about them?

We were impressed with their senior leadership and their ability to recognize business opportunities. I would definitely reach out to FLEX again if I see an opportunity. 

Are there any areas they could improve?

It’s hard to say because we basically told them what the service levels were and they raised the bar high — they met every criterion that we put in front of them.

Do you have any advice for potential customers?

If you plan on working with FLEX, make sure to match the right facility with the components you’re trying to make. You have to be in the shop and you have to have the right leadership that is going to get you the priorities — they’re a big company, so you could get swallowed up really quickly.

BACKGROUND

Introduce your business and what you do there.

I was the VP of a telecommunications company. We provide automotive connectivity modules for several original equipment manufacturers (OEMs) within the automotive industry. 

OPPORTUNITY / CHALLENGE

What challenge were you trying to address with FLEX?

We needed help in manufacturing four-layer printed circuit boards (PCB). 

SOLUTION

What was the scope of their involvement?

We had used FLEX on and off for various projects, mainly for the production of connectivity solutions of various types. They reviewed PCB designs and manufactured four-layer PCBs. Additionally, they conducted final drilling tests, visual inspections, and bench tests.

Their deliverables included connectivity modules for busses, electric vehicles, construction equipment, and remote controls for marine platforms. They had also assisted us during quality inspections to review our processes when we were getting an ISO accreditation. 

What is the team composition?

I have worked with around 20 people through the years, including a plant manager, test engineers, electrical engineers for reviews of PCBs, and a head of quality management. 

How did you come to work with FLEX?

Our company sold its factory to FLEX. Even as they moved production to another site, we followed them because of the exceptional quality of work that they could deliver. 

How much have you invested with them?

For this project alone, we have spent around $5 million. 

What is the status of this engagement?

The project started around early 2000, and it went through various iterations all the way up until 2018. 

RESULTS & FEEDBACK

What evidence can you share that demonstrates the impact of the engagement? 

FLEX met all our goals for the project. They had followed all the required quality management processes in the production lines. Test results from each batch produced came out good. We have followed up at our own facilities with special inspections, bench tests, and checking, and the PCBs they manufactured were within specifications. We only had a few units that encountered issues. 

How did FLEX perform from a project management standpoint?

FLEX was extremely professional and good at communicating any issues they encounter. 

What did you find most impressive about them?

Their professionalism set them apart, as well as the quality of their work. They had defined processes and clear communication. Their reviews of layouts of designs of PCBs had worked out really well. 

Are there any areas they could improve?

They could improve their lead times. Sometimes, we had unforeseen events and we encounter issues, though they were very minimal. 

Do you have any advice for potential customers?

Be in close contact with their team, visit the factory, and know the key people you’re going to be communicating with from FLEX.