A manufacturer running a mature serial production system faced a critical risk: the original encoder supplier had discontinued the component. The system relied on two separate encoders performing complementary tasks, and a like-for-like replacement simply didn’t exist.
After a thorough analysis of the system’s environment, mechanical constraints, and performance requirements, we collaborated with a trusted supplier to develop a fully custom encoder. The new unit performed both tasks of the original pair — within the footprint of a single encoder — while exceeding the original specifications.
The solution completed full development, rigorous testing, and entered serial production without disrupting the customer’s operations.
Supply risk | Eliminated — an immediately available replacement secured continuity |
Footprint | Two encoders consolidated into one, reducing volume and weight |
Performance | Exceeded the original specification |
Cost | Lower total cost than the original two-encoder setup |
