A North American manufacturer of industrial automation controllers faced a critical challenge: they needed to ramp up production of a new generation of IoT-enabled edge devices but lacked the internal capacity for final system integration, enclosure sourcing, and global logistics. Their existing supply chain fragmented across multiple vendors—PCBs from one supplier, enclosures from another, final assembly outsourced to a third—resulting in extended lead times, quality inconsistencies, and complex logistics coordination.
The client’s product required:
With no single supplier capable of managing the entire workflow, the client faced a six-month backlog and risked losing market share to faster-moving competitors.
Weller’s engineering and supply chain teams proposed a turnkey full box build solution, consolidating all manufacturing steps under one roof:
Integrated Supply Chain – We sourced all components (PCBs, passives, connectors, AL6061 blanks, fasteners) through our global network, eliminating the client’s need to manage multiple purchase orders.
Parallel Processing – While PCBs were fabricated and assembled in our facility, we simultaneously machined enclosures and prepared the final assembly line.
Final Assembly & Testing – Each unit underwent full box build assembly, including PCB mounting, connector integration, environmental sealing, and 100% functional testing under simulated field conditions.
Direct Shipping – Finished products were packed, palletized, and shipped directly to the client’s distribution centers
By consolidating all processes with a single partner, the client achieved:
| Metric | Before | After |
|---|---|---|
| 26 weeks | 9 weeks | |
| 4 | 1 | |
| 87% | 98.5% | |
The first 500 units were delivered in just 8 weeks—four weeks ahead of the accelerated schedule. Production scaled to full volume without interruption, and the client successfully launched their product ahead of competitors.
This project demonstrates the power of a single-source, full box build partnership in accelerating time-to-market while reducing supply chain risk. By integrating PCB fabrication, assembly, enclosure manufacturing, and final testing under one roof, Weller helped our customer eliminate coordination overhead and focus on their core business—delivering innovative automation solutions to their end customers.
For OEMs facing similar complexity, a streamlined full box build approach can transform fragmented production into a reliable, scalable, and fast-to-market engine.
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