How we did it

Real projects with numbers, timelines, and client quotes. No marketing fluff.

Industry:

Service:

IndustrialSupplier Audit in China

Shenzhen Supplier Audit: Uncovering a "Factory" with No Manufacturing Capacity

Electronics Manufacturer (Russia)

«A supplier in Shenzhen positions itself as an OEM factory producing IP67 connectors. Pricing was 35% below market, MOQ was flexible, and ISO 9001 arrived by email within two days. The situation felt too good to be true. Before signing a $340K contract, an independent verification was required.»

Business License Verification and Cross-Check Across 8 Registries

Verified the Unified Social Credit Code in 8 registries. Findings: the company was registered as a trading firm, not a manufacturer. Registered capital: 100K RMB — 50× below the typical level. Owner: 6 other companies, 2 on the debtor blacklist.

Unannounced Site Visit

Conducted a surprise audit on a regular workday. The "production floor" turned out to be a 200 m² rented office with 12 employees. Equipment: 2 benchtop presses. Actual capacity: ~500 pcs/month instead of the claimed 50K.

Subcontractor Chain Analysis via Documentation

Requested COC, material test reports, and 6 months of batch records. Identified 3 different barcode printers, 7 packaging formats, and mismatched batch numbers. Direct evidence of resale from at least 3 sub-suppliers.

23/100 (critical)

Score

$340K prevented

Contract

11 days

Duration

7 risk factors

Red flags

92/100 found

Alternative

«In 11 days we saved $340K and six months of dealing with an unreliable supplier. The report was so detailed that we used it as a checklist for vetting four more potential partners.»
— Procurement Director

TelecomImport Substitution

Import Substitution of Xilinx/Intel FPGAs on 47 Telecommunication Units

Telecom Operator (Russia)

«47 units of telecom equipment with Xilinx 7-series and Intel Cyclone V FPGAs. Sanctions cut off supply, stock covered 8 months. Migration to Russian (Milandr) or Chinese (Pango, Gowin) alternatives was required. On 23 devices the FPGA operates alongside DDR3 and PCIe Gen2.»

Parametric Search with Pin-to-Pin Compatibility

Developed an automated script that compared 340+ parameters of each FPGA die against the requirements of each of the 47 devices. The analysis phase shortened from 6 weeks to 4 days.

Migration via Intermediate Adapter Board for 12 Devices

For 12 devices with critical timing dependencies, we developed mezzanine adapter boards, reducing time-to-market from 8 months to 10 weeks.

Timing Verification in 3 Independent Tools

Cross-verification in vendor tool, OpenSTA, and our own Python framework. Detected 14 hidden timing violations that the vendor tool did not show. Fixing them before prototyping saved 6–8 weeks of debugging.

24+ months supply

Stock

100% closure 200 MHz+

Timing

44/47 migrated (93.6%)

Devices

−22%

Savings

156 days

Duration

«Our biggest fear was that the redesign would drag on for years and half the devices would not work. In 5.5 months we migrated 44 of 47. Three complex cases were solved with adapter boards — the equipment works, timing is clean.»
— Chief Technology Officer of Telecommunications Infrastructure

MedTechPCB Design

12-Layer HDI Board for a Portable Ultrasound Scanner: MDR Class IIb

Medical Device Manufacturer (Russia)

«Development of a portable ultrasound scanner. Required a 12-layer board with HDI (0.1 mm microvia), 4 GHz signal traces, and an analog path with noise < 2 nV/√Hz. MDR Class IIb certification was required.»

Dedicated Analog and Digital Signal Layers

Dedicated layers 3–4 exclusively for the analog path with guard rings and stitch vias every 2.5 mm, reducing crosstalk from −42 dB to −68 dB.

Thermal Profile Emulation Before First Prototype

Ran 140 simulations in Icepak before the first prototype, optimizing placement of 23 heat-generating components. Iterations reduced from 4–5 to 2.

Automated Design History File Generation

Configured a CI/CD pipeline that automatically generated BoM revisions, diff reports, and test protocols. Certification prep shortened from 3 months to 2 weeks.

First-iteration pass

EMC

94 dB

SNR

112 days

Duration

2 instead of 4–5

Prototypes

2 weeks

Certification

«The previous contractor had not even gotten us to a third prototype in 8 months. Here, in 16 weeks — a working board that passed EMC on the first try.»
— Project Manager, Medical Imaging Division

IndustrialSoftware Development

Monitoring Platform for 200+ Industrial Sensors: Latency < 500 ms at 50K Events/sec

Manufacturing Company (Russia)

«217 sensors (vibration, temperature, current, pressure) across 4 production lines. A real-time platform was required, with anomaly detection (false positive < 5%) and predictive maintenance 72 hours before failure. Load: 50K events/sec.»

Edge Computing on ARM Cortex-A53 Instead of Cloud Processing

Deployed edge nodes on each line, performing FFT and feature extraction locally. Network traffic dropped by 94%, latency stayed below 500 ms even during communication outages.

Ensemble Model of 3 Algorithms for Anomaly Detection

Used an ensemble: LSTM + Statistical Process Control + One-Class SVM. Weighted voting reduced the false positive rate from 18% to 3.2%.

Digital Twin with Physical Simulation

Built simplified physical models of 12 critical assemblies in Simulink, integrated with the ML model. Mean failure prediction horizon: 78 hours versus 34 hours with ML alone.

340 ms (p99: 480)

Latency

217 sensors

Sensors

−67% downtime

Downtime

185 days

Duration

3.2%

False positive

«Before, we learned about a failure when the machine was already down. Now we get a notification 3 days in advance with the specific assembly and recommended action. Downtime dropped by two-thirds.»
— Chief Digital Transformation Officer

DefenseComponent Sourcing

Urgent Delivery of 847 China-Independent Components for Serial Radar Production

Large Defense Enterprise (Russia)

«Serial production of a next-generation radar station needed to start. 847 positions in the BOM were on the sanctions list or had a single supplier in China. Deadline: 45 days before the production line stopped.»

Parallel Engagement with 23 Suppliers Instead of 1–2

Split the positions into 7 clusters by component type and launched parallel negotiations with 23 suppliers in 9 countries. The sourcing phase shortened from a typical 4–6 weeks to 8 days.

Alternative Certification for 34% of Positions

For 287 positions, we found alternatives with a wider temperature range (−60…+150°C instead of −40…+125°C), expanding the pool of available suppliers by a factor of 3.2.

Pre-Booking at Singapore Warehouses

For 156 positions with long lead times, we reserved stock at regional warehouses before negotiations were finalized, gaining a 14-day logistics head start.

847 positions

Items

−12%

Savings

98.7%

Coverage

38 days

Duration

67% China-independent

Diversification

«38 days instead of 120 — and that with 847 positions. The line did not stop. For the first time in 3 years we received a complete BOM without deviation approvals on every third item.»
— Head of Supply Department

How we did it

Case studies

Shenzhen Supplier Audit: Uncovering a "Factory" with No Manufacturing Capacity

Business License Verification and Cross-Check Across 8 Registries

Unannounced Site Visit

Subcontractor Chain Analysis via Documentation

Import Substitution of Xilinx/Intel FPGAs on 47 Telecommunication Units

Parametric Search with Pin-to-Pin Compatibility

Migration via Intermediate Adapter Board for 12 Devices

Timing Verification in 3 Independent Tools

12-Layer HDI Board for a Portable Ultrasound Scanner: MDR Class IIb

Dedicated Analog and Digital Signal Layers

Thermal Profile Emulation Before First Prototype

Automated Design History File Generation

Monitoring Platform for 200+ Industrial Sensors: Latency < 500 ms at 50K Events/sec

Edge Computing on ARM Cortex-A53 Instead of Cloud Processing

Ensemble Model of 3 Algorithms for Anomaly Detection

Digital Twin with Physical Simulation

Urgent Delivery of 847 China-Independent Components for Serial Radar Production

Parallel Engagement with 23 Suppliers Instead of 1–2

Alternative Certification for 34% of Positions

Pre-Booking at Singapore Warehouses

How we did it

Case studies

Shenzhen Supplier Audit: Uncovering a "Factory" with No Manufacturing Capacity

Business License Verification and Cross-Check Across 8 Registries

Unannounced Site Visit

Subcontractor Chain Analysis via Documentation

Import Substitution of Xilinx/Intel FPGAs on 47 Telecommunication Units

Parametric Search with Pin-to-Pin Compatibility

Migration via Intermediate Adapter Board for 12 Devices

Timing Verification in 3 Independent Tools

12-Layer HDI Board for a Portable Ultrasound Scanner: MDR Class IIb

Dedicated Analog and Digital Signal Layers

Thermal Profile Emulation Before First Prototype

Automated Design History File Generation

Monitoring Platform for 200+ Industrial Sensors: Latency < 500 ms at 50K Events/sec

Edge Computing on ARM Cortex-A53 Instead of Cloud Processing

Ensemble Model of 3 Algorithms for Anomaly Detection

Digital Twin with Physical Simulation

Urgent Delivery of 847 China-Independent Components for Serial Radar Production

Parallel Engagement with 23 Suppliers Instead of 1–2

Alternative Certification for 34% of Positions

Pre-Booking at Singapore Warehouses