Over the years, PICA Manufacturing Solutions (PICA) has not only mastered the art of supporting customers in designing and engineering innovative products but has also excelled in managing all aspects of manufacturing and the supply chain to ensure successful market launches. This proficiency led to the acquisition of Nel-Tech Lab in 2016, a design and manufacturing firm based in Derry, NH. This acquisition was aimed at harnessing Nel-Tech Lab’s unique technological capabilities and market position to develop PICA’s own Internet of Things (IoT) technologies under the innovative Skyhawk technology platform—a suite designed to enhance IoT connectivity and functionality. It also facilitated the launch of innovative product lines such as Trapmate and Oversea.
Manufacturing these technologically advanced products is managed at PICA’s own facility in Derry, NH. This facility is equipped with comprehensive manufacturing capabilities, where prototypes are meticulously produced and tested. This is done in close partnership with the Skyhawk engineering team, ensuring that each prototype meets the high standards set by PICA before moving to mass production.
The manufacturing prowess of PICA does not stop in Derry. To meet global demand and scale production efficiently, PICA utilizes its facility in Kuala Lumpur, Malaysia. This location was selected for its proximity to key markets and suppliers, its economic benefits, and its capacity to optimize production capabilities and logistics. This strategic geographic diversification ensures that PICA can reduce lead times and enhance customer satisfaction worldwide.
Recently, the Skyhawk team entrusted PMS with a significant challenge—to build an inventory of 20,000 units of a new sensor. Rising to the occasion, PICA deployed its refined "Carbon Copy" methodology across its facilities including rigorous training, extensive documentation, and precise validation to ensure that no changes will be made at any stage of the process. This method guarantees that every unit produced in Kuala Lumpur mirrors those developed in Derry, maintaining product uniformity and quality across global scales.
The results have been stellar. The collaborative efforts between the teams in Derry and Kuala Lumpur have not only met but exceeded expectations. The seamless integration between design finalization, product line setup in Derry, and mass production transfer to Kuala Lumpur facilitated the manufacture of the 20,000 sensors and associated hubs in record time.
By strictly adhering to its Carbon Copy principles and effectively implementing vertical integration, PICA has not only demonstrated its robust capabilities but also established a benchmark for precision in technology development and manufacturing.