About the Client
A mid-size fabless semiconductor company was preparing for its first large production run. While their chip design was proven, they needed to be confident that their manufacturing partners could meet their production goals. They had to assess their packaging, testing, and assembly partners’ (OSATs) ability to hit yield and capacity targets before signing any long-term contracts.
The Challenge
Scaling risks
Production at a larger scale could expose new issues that didn’t appear in smaller pilot runs.
Supplier uncertainty
The company needed to be sure its partners could meet production timelines and had the necessary experience.
Cost and logistics
The client needed to understand potential costs and how to structure contracts to protect its margins and schedule.
Our Approach
We helped the company by providing targeted insights through a structured process:
Expert Sourcing
We screened and interviewed a wide range of experts, including process engineers, operations heads, and procurement leads from similar companies.
Targeted Interviews
We conducted in-depth interviews using a tailored guide that addressed the company’s key concerns, such as common production failures, realistic timelines, and expected rates of scrap or rework.
Reference Triangulation
We performed follow-up checks with previous customers and former employees of the client’s top two preferred partners to verify their claims.
Actionable Synthesis
We summarized all the information into a concise report that provided a clear comparison of each supplier’s technical readiness and risks. This included specific, actionable recommendations for contract negotiations.
Outcome
Our work gave the client the clear, data-driven insights they needed within three weeks. The findings helped them adjust their initial yield expectations and reduce the overall production timing risk. The client was able to use our recommendations to make more informed decisions about their supplier contracts and ultimately launch their product with a reliable and cost-effective strategy.
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