Some manufacturing solutions require a great deal of development and
production of component parts as well as assembly. This was true in this
case study, where Mars International acted as a manufacturing partner
providing both plastic and metal components.

Business Situation
Mars International client of Natick, MA was established by the venture
engineering firm, Manifold Products, also based in Natick.

Outsmart has developed a unique, intelligent energy management system that
“transforms a building’s existing electrical wiring infrastructure into a
real-time power management network.”

This system takes advantage of the infrastructure using OutSmart’s
proprietary powerline protocol turning it into a communication network for
power consumption data. It can monitor how much electricity is being used
at specific locations wherever an EnergyMate module is deployed, thus
providing visibility into energy costs, equipment performance, and
electrical infrastructure. Building owners and facility managers can
remotely monitor the data through a web-based dashboard to make energy
consumption decisions to lower the total cost of building ownership.

Technical Situation
For its new product introduction, OutSmart sought a manufacturing partner
that could design the tooling and manufacture the entire set of products
including several EnergyMate modules, the LoadRunner aggregator, and the
LoadMaster modem. The initial criteria for OutSmart were to find a
manufacturing partner with highly skilled design engineering talent such
that the tooling could be designed and perfected for each metal and
plastic component of each product according to their design
specifications. The company wanted a partner with the flexibility to
initially support low volumes and to deliver individual non-assembled
components to OutSmart for their analysis and approval. At the same time,
this partner had to have the ability to support a significant volume ramp
with a low-cost solution once the product launch was successful.
Ultimately, their manufacturing partner would manufacture and assemble the
complete product. OutSmart’s engagement with Mars International initially
focused on the heart of the system, the EnergyMate, which is a high volume
low-cost sensor that turns existing electrical breakers into smart nodes
in the system.

OutSmart delivered product requirements and 2D drawings for two EnergyMate
versions: 1-up and 3-up. Each version required the design of many
intricate plastic and metal components. Mars’ electronics engineers were
asked to design tooling for 9 injection molded plastic components and 5
metal stampings and castings, including the front and back housings, screw
blocks, screws, latches, bushings, and clamps. Although the EnergyMate
product was the primary focus of product development, Mars International
designed tooling for several other products OutSmart has developed and
plans to commercialize.

Solution & Benefits
From the 2D drawings provided by OutSmart, Mars International designed the
molds and dies for each individual component for the EnergyMate products.
These designs took into consideration ease-of-manufacturing and assembly,
and overall costs, so that the final product assembly would meet the
product goals outlined by OutSmart. Manufacturing of each component
commenced and were delivered unassembled to OutSmart for their analysis
and product builds. Mars supplied assembly recommendations to OutSmart for
their consideration in product assembly. After a thorough evaluation of
each component and of the product assembly process, OutSmart approved all
of the components. They have fully assembled their EnergyMate products and
have begun initial product installations in various locations in North
America. OutSmart and Mars International have prepared for full
commercialization of the product as deployments of the OutSmart Power
System continue to grow.

OutSmart was able to bring their product to market rapidly and
cost-effectively by partnering with Mars International for their design,
manufacturing, and assembly expertise. The advantage of working closely
with a U.S.-based company, while still capturing the benefits of offshore
manufacturing, allowed OutSmart to meet their product launch targets.
Plans are currently underway to transition the complete product build to
Mars International for volume production.

If you need help with your tooling design and build as well as the final
manufacturing of the component parts, consider Mars International. With
decades of experience in developing manufacturing solutions, we offer a
turn-key approach to all of your production needs.

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