Contec Helps Lookout Worldwide Lower Manufacturing Costs Dramatically While Ensuring Reliability
- Customer
- Lookout Worldwide Inc.
- Industry
- Medical & Healthcare
- Goals
- Cost savings, Space saving
Contec designed and manufactures the Ambush alarm system for boats and industrial equipment, cutting manufacturing costs by more than 50 percent while improving reliability.
Overview
Lookout Worldwide asked Contec to design, develop and produce Ambush, an alarm system for boats, vessels and industrial equipment that helps prevent theft and recover stolen property. It detects far smaller shifts in alignment and location than GPS alone and can alert authorities before a vessel drifts more than a few feet. Ambush combines GSM radio and Iridium satellite communication, a digital compass, GPS, accelerometers, firmware and software linked to an online database.
Challenge
All of this had to fit in a small package with low manufacturing cost and top performance and reliability. Ernie Sosa, Lookout’s Vice President and Marketing Manager, said the product had to stay competitively priced and “it had to perform at the highest level.” Lookout chose Contec after touring its manufacturing facility.
Solution
Working closely with Lookout’s engineers, Contec took over design and manufacturing with a focus on cost:
- One platform for both the cellular and satellite versions, so one minimum component buy covers both devices
- A two-layer printed circuit board, where less capable competing products used four to eight layers
- All parts on the top side of the board, so the PCB shop needs one pass instead of two
- Built-in automated testing
- Lower-cost components that meet or exceed reliability standards
- Surface-mount components for easy assembly and the largest labor savings
Results
Contec cut Ambush manufacturing costs by more than 50 percent. Sosa estimated surface-mount assembly saved 30 to 40 percent and the two-layer board another 15 percent. Machine-controlled soldering produces consistent builds, a stable low-current power supply limits battery drain, and the ungrounded system withstands power surges when boats start.
Contec also manages the Ambush warranty program, including repairs and administration, and pushed to make both versions significantly smaller than planned, giving owners more ways to conceal the devices onboard.
Originally published by Contec Co., Ltd. at contec.com.