Solar Power System: IP Crisis to Design and Manufacturing Independence
When suppliers hold your IP hostage,
you need a partner who moves fast and manufactures anywhere.
Explore
Formulate: Misplaced IP Ownership Risks Operations
Customer discovered their manufacturer owned IP rights to their product: Residential solar systems funding life-enhancing devices for people in need
Legal battles offered no immediate solution while end-users waited for products that couldn’t be manufactured and would never be delivered
IP disputes can destroy businesses overnight, and we got called to solve what lawyers couldn’t: Complete product redesign and manufacturing independence
Create
Engineer: Parallel Development Accelerates Recovery
Complex product redesigns can take years – we redesigned a manufacturable alternative in six months from proof-of-concept sign-off
Season Group‘s UK facility simultaneously produced buffer volumes of substitute products, giving customer confidence to break supplier dependency
Coordinated dual-track approach – redesign and interim manufacturing – that most IoT companies simply can’t execute
Deploy
Deploy: Global Manufacturing Footprint Delivers Flexibility
Production lines were operational across UK and China facilities only nine months after our first engagement with customer
Geographic diversity enabled volume adjustments based on actual market demand rather than manufacturing constraints
Seamless transition from crisis response to full-scale production without supply chain disruptions
Scale
Scale: Partnership Expansion Beyond Original Scope
Weekly production ramped to thousands of units as demand exceeded all projections
Reassigned production staff and expanded assembly lines while maintaining delivery schedules
Solving one critical problem well opens doors to solving more: Success launched ongoing partnership for material sourcing and continuous design development
Enterprise IoT succeeds when manufacturing backbone matches innovation speed.
