Client Background
Gridware is transforming electrical grid safety with advanced sensing and analytics solutions that help utilities detect and respond to threats such as wildfires before they escalate. By combining real-time data with predictive insights, Gridware enables utilities to protect infrastructure, reduce downtime, and safeguard communities.
As thousands of first-generation devices were already deployed in the field and next-generation products were under development, Gridware recognized that reliability would be critical to their growth and long-term success. They engaged Product Realization Group (PRG) to build a comprehensive reliability program that could ensure current products performed in the field and future designs met aggressive lifetime expectations.
“PRG’s on-demand expertise allowed us to build essential programs in reliability, quality, and supplier management well before we had in-house resources. Their leadership in DFMEA, testing strategy, supplier quality, and even hiring made them an essential partner in scaling our business with quality built in from the start.”
— Jim Reich, Director of Hardware Engineering, Gridware
Challenges
Gridware faced several critical reliability challenges
- Limited internal reliability expertise and no structured processes to guide development.
- Undefined product performance and lifetime requirements, making it difficult to validate designs.
- Absence of risk assessments such as DFMEA to identify potential failure modes.
- Limited testing infrastructure or partnerships for accelerated reliability validation.
- Lack of verification and validation plans to confirm product robustness in extreme environments.
PRG’s Solution
Establishing Reliability Requirements
PRG collaborated with Gridware leadership and engineering teams to translate field data into measurable reliability requirements, including a ten-year survival target in harsh outdoor conditions. These requirements became the foundation for validation strategies and reliability testing plans.
Proactive Risk Mitigation
We led DFMEA workshops to identify, quantify, and prioritize potential failure modes early in the design process. The team also conducted a critical review of the bill of materials, flagging and replacing components that posed risks under temperature, humidity, or corrosion stress. Recognizing the importance of battery performance, PRG developed a dedicated battery life testing methodology with custom fixtures and accelerated test protocols.
Building Reliability Testing Infrastructure
PRG helped Gridware transition from having no reliability testing capability to a fully functional, multi-site infrastructure. We designed and established an in-house lab equipped with temperature and humidity chambers and specialized battery cycling systems. In parallel, we coordinated accelerated testing at third-party and contract manufacturer facilities and performed root-cause analysis on failures discovered during testing. This provided a comprehensive understanding of product reliability at both the PCBA and system levels.
Enabling Long-Term Reliability Expertise
Beyond program development, PRG supported Gridware in recruiting and training internal reliability engineers, transferring knowledge, and institutionalizing best practices. We also defined supplier quality requirements and supported contract manufacturer selection to ensure reliability expectations extended through the supply chain.
Results
Over an intensive eight-month engagement, PRG enabled Gridware to
- Define clear, measurable reliability requirements aligned with field performance goals.
- Build a structured risk management process, including DFMEA and component-level reliability assessments.
- Establish internal and external reliability testing capabilities.
- Identify and resolve critical design issues before production scale-up.
- Develop internal reliability expertise to support future product generations.
With these foundational programs and capabilities in place, Gridware is now equipped to scale confidently, deliver products that meet demanding environmental and performance requirements, and accelerate the development of future generations with reliability built in from the start.
Services Delivered:
- Reliability engineering strategy and program development
- DFMEA facilitation and risk analysis
- Component-level reliability assessment and BOM review
- Battery life validation methodology and testing
- In-house lab design and test infrastructure development
- Accelerated testing execution and root-cause analysis
- Supplier quality planning and CM selection support
- Reliability team recruitment, training, and knowledge transfer
Ready to bring your next product to market with confidence? Contact PRG to learn how our experts can help you enhance product reliability.
