The Challenge
End-of-life component announcements can bring production lines to a grinding halt. Our client discovered their critical Motor Driver IC was being discontinued, creating an urgent threat to ongoing manufacturing operations.
They needed a solution that maintained production efficiency while avoiding costly investments in new testing infrastructure during an already challenging transition.
Our Solution
We transformed this supply chain crisis into an opportunity for improved design resilience and cost optimization:
Discrete Component Redesign: Rather than searching for another potentially vulnerable IC, we completely reimagined the motor driver circuitry using discrete components, creating a supply-resilient solution.
Production-Ready Integration: By designing the new circuitry to work with existing Production Functional Test (FCT) fixtures, we eliminated the need for costly new test equipment investments.
Accelerated Validation Program: Implemented comprehensive reliability testing including hot and cold burn-in tests and Highly Accelerated Life Testing (HALT) to ensure the new design exceeded original specifications.
Results That Drive Success
- Eight weeks: Two complete PCBA cycles built and functionally verified
- Four weeks: Full reliability testing program completed
- Zero fixture modifications: Seamless integration with existing production infrastructure
- Cost savings achieved: Through elimination of new test equipment investments
- Enhanced supply resilience: Discrete component design reduces future EOL risks
