From challenge to solution: How Factbird transitioned its IIoT device production to Europe

Company 

Factbird empowers manufacturers to boost operational efficiency and minimize waste by driving informed decision-making and engaging the workforce. 

The Factbird solution is simple to deploy and delivers rapid results. It comprises a cloud software suite and an IIoT edge device, Factbird® DUO, designed to seamlessly capture multisource industrial data and securely transmit it to the cloud. The cloud software suite includes three powerful applications: Production Insights, Connected Operations, and Knowledge Excellence, each tailored to optimize production, empower the workforce, and drive sustainable growth.

Rooted on the shop floor, Factbird serves manufacturers worldwide, helping them boost productivity and remain competitive in a rapidly changing industrial landscape.

Challenge

Factbird’s journey to scale hardware production as it grew brought some challenges that included

• Quality and supply chain issues: Communication problems, inconsistent product quality, and geopolitical instability disrupted their supply chain with an Electronic Manufacturing Service (EMS) provider outside Europe. Trade agreements and delayed deliveries further impacted their ability to serve customers on time.
• Scaling needs: As demand grew, Factbird needed to move from manual in-house testing to automated processes, while ensuring compliance and navigating export complexities.
• Shift in strategy: Factbird sought to bring production closer to Denmark to improve proximity and oversight. However, they faced a unique challenge in Europe:
  • Small EMS providers lacked the capacity for low-volume, high-complexity manufacturing.
  • Large EMS providers prioritized high-volume contracts, making them unsuitable for FACTBIRD’s niche requirements.

Solution

Factbird partnered with TECHTO Electronics, the manufacturing division of EKTOS. TECHTO specializes in flexible, full-service EMS solutions for high-volume and small-batch productions. They seamlessly bridge the gap between design, firmware, and efficient manufacturing for IIoT devices.

The collaboration began with a streamlined contract process and tailored production setup whereby:

• Factbird integrated pre-existing contingency stock into the production process.
• TECHTO’s New Product Introduction (NPI) team worked closely with Factbird, providing insights that enhanced product design and streamlined manufacturing.

Using their box-build expertise, TECHTO efficiently executed low-batch production of the Factbird® DUO, delivering high-quality units on schedule. As a Danish company with manufacturing facilities in Denmark and Ukraine, TECHTO offered cost-effective solutions while maintaining high standards.

Results

The partnership with TECHTO yielded transformative outcomes and established a strong foundation for scalable, high-quality production to meet future demands.  TECHTO ensured

• Timely Deliveries: Both prototypes and serial production batches were delivered on time, fully tested, and verified.
• Enhanced Product Quality: The collaboration resulted in notable reductions in device failure rates and valuable product refinements.
• Simplified Logistics: Producing through a European EMS eliminated export regulations and shipping concerns.
• Scalable Production: TECHTO’s adaptability ensured seamless adjustments across multiple production batches that supported Factbird’s growth.

Additionally, Factbird utilized EKTOS Testing and Reliability Services (TRS) to enhance product compliance, quality, and design. This partnership has laid the foundation for developing the next generation of Factbird devices, with even greater performance and reliability. Manufacturers can rest assured of continuously driving efficiency.

Customer Quote / Testimonial

“We have had a very good experience with TECHTO and EKTOS. The transition to their European EMS has been seamless. We ship components and receive high-quality, well-manufactured products without any concerns about shipping or export regulations. Despite moving our production from the Far East to Europe, we have experienced no price increases”. 

Martin Kirkegaard,
IoT Hardware & Operations Manager at FACTBIRD