Client: Synopsys
Product: HAPS-200 FPGA-Based Pre-Silicon Prototyping System
PRG Solution: NPI Leadership
Result
Successful production ramp of a complex product in under 4 months, achieving double the manufacturing capacity at competitive cost and quality levels. This rapid transition was made possible through integrated NPI leadership, custom tooling, visual assembly documentation, scalable test infrastructure, specialized technician training, and continuous quality improvement.
“PRG was an outstanding partner throughout the HAPS -200 volume production effort. They provided operational leadership, hands-on engineering support, and program discipline we needed to meet an aggressive schedule for a very complex product. Their expertise in NPI, manufacturing readiness, and quality systems was instrumental to our success.”
— Robert Bisaillon, VP of Operations, Synopsys
The Challenge: Manufacturing a Technically Demanding System at Speed
Synopsys faced a critical challenge: meeting the soaring global demand for its high-performance HAPS-200 system. This sophisticated multi-FPGA prototyping platform, essential for pre-silicon validation of advanced SoCs, features mechanical integration, high performance PCB assemblies, and high-speed interconnects. Proper handling, precise routing, and stringent inspection of these components were paramount to ensuring Synopsys high quality standards and system-level performance.
To increase production capacity, responsiveness, and control, Synopsys made the strategic decision to expand production capacity in a second CM Factory. The goal: rapidly ramp up production of this technically demanding product without sacrificing yield or quality.
Integrated NPI Leadership: PRG & Synopsys Operations
To navigate this pivotal transition, Synopsys partnered with Product Realization Group (PRG) to lead the New Product Introduction (NPI) effort alongside its internal operations team. PRG provided both strategic direction and hands-on execution, orchestrating all facets of the aggressive ramp and ensuring a seamless transition.
Key contributions included
- Leading NPI planning and schedules
- Coordinating and validating custom fixture designs with CM engineering
- Developing exploded-view assembly documentation to ensure technician clarity and repeatable assembly practices.
- Designing and delivering custom training for complex cable handling, routing, strain relief, and inspection.
PRG also supported the expansion of board and system-level test infrastructure in parallel with build rates and helped to manage quality tracking and improvements. The on-the-ground presence at the CM, acting as the “eyes and ears” of the program ensured daily alignment across teams, active process improvement and rapid issue resolution.
Manufacturing Execution
PRG worked as a direct extension of the Synopsys team, collaborating closely with “on-the-ground” presence at the factory to ensure a controlled and scalable production launch.
Highlights
- Program Coordination: Led cross-functional planning and execution, keeping all stakeholders aligned and resolving issues in real time.
- Technical Responsiveness: Proactively coordinated Synopsys and factory resources to address manufacturing or test blockages quickly—dramatically improving issue resolution times and avoiding schedule slippage.
- Fixture Development: Led custom fixture design to support repeatable and ergonomic builds.
- Visual Work Instructions: Produced exploded-view diagrams to streamline training and reduce assembly errors.
- Cable Assembly Training: Delivered technician training focused on high-density cable assembly and quality checks to improve first-pass yield.
- Scalable Test Infrastructure: Worked closely with Synopsys engineering and operations teams to expand test capacity to match increased production throughput without bottlenecks.
- Yield & Quality Management: Drove defect tracking, root cause analysis, and continuous improvement loops to improve quality across increasing build cycles.
Results
- Full Production Ramp in Under 4 Months
Despite product complexity, full-scale production was scaled up rapidly to meet rising demand. - Increased Yields Through Focused Technician Enablement
Targeted technician training and optimized tooling significantly improved first-pass yields, reduced rework and enhanced build consistency. - Continuous Yield Improvement
Yield tracking and structured feedback enabled fast identification and correction of systemic issues. - Scalable Manufacturing and Test Build Flow
Test infrastructure was scaled in lockstep with production, avoiding bottlenecks and delays.
Summary
The HAPS -200 program represents a best-in-class NPI to Volume Production success—driven by close coordination between Synopsys, Product Realization Group, and the Contract Manufacturer. In less than four months, the team transitioned a technically complex hardware system to a new manufacturing line.
Success Factors
- Strategic and tactical NPI leadership by PRG
- Close coordination with Synopsys Operations and the CM
- Custom assembly fixtures and visual work instructions
- High-density cable assembly training
- Synchronized expansion of test capabilities
- On-site oversight and agile issue resolution
- Continuous quality and yield improvement
PRG’s leadership was central to this outcome—guiding not only program timelines but the tactical infrastructure required to scale complex hardware products with precision, quality, and speed.
At PRG, we help innovative companies navigate complexity and scale smarter. Contact us to learn more about how we can support your next launch
