Electrical Control Panel Solutions

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Electrical Control Panel Solutions

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Electrical Control Panel Fabrication Overview

Brock Solutions operates one of the largest CSA Certified and UL Listed panel fabrication operations in North America. Whether your needs are project-based or looking for panel fabrication outsourcing services, we are focused on optimizing your total cost of ownership. Brock Solutions is focused on quality, continuous improvement and developing long term partnerships with organizations across a variety of industries. We work with companies looking to improve quality, optimize their supply chain and drive costs out of their business. Our approach is to gain an understanding of our clients business and develop strategies to achieve their goals. Our engineering depth and ample capacity allow us to deliver large complex systems from either of our facilities in the US or Canada and our volume purchasing power ensures the most competitive material pricing and on time delivery.

Companies that manufacture their own panels often struggle with consistency, quality, competitiveness and the unsettling fluctuations in work volume and resources when it is not their core focus. Panel fabrication is our core focus, and quite simply, is what we do day in and day out.

Panel Services offered include:

Project/Program Management

Project/Program Management

Design

Design

Electrical design
CAD

Panel Fabrication

Panel Fabrication

Custom assemblies
High volume manufacturing
Custom bus bar solutions
Liquid cooled drives

Material Procurement

Material Procurement

Centralized materials management
Volume purchasing power

Testing / QA

Testing / QA

– Fully documented Panel Test and Quality Procedure
– Full Load Testing
– Factory Acceptance Testing (FAT)
– Panel Certification to CSA and UL
– All tests and quality checks are fully document and traceable to the assembly level

Logistics

Logistics

Cross border shipments
Incoming goods
Shipment of final product to customers globally

On-site Services

On-site Services

Panel Fabrication
Machine Wiring
Installation
Commissioning and Startup

Outsourcing / Contract Manufacturing

Outsourcing / Contract Manufacturing

Control Panel Fabrication Operations

Brock Solutions operates one of the largest CSA-Certified & UL-Listed panel fabrication operations in North America. Highlights include:

Panel manufacturing facilities in both Kitchener, Ontario, Canada, and Irving, Texas, US

  • 50,000+ square feet of capacity
  • Designed for both highly customized and high volume repetitive manufacturing requirements
  • Full-scale manufacturing of “Engineered-to-Order” pre-wired and pre-tested Packaged Control Rooms (PCRs)
  • Wide range of power sources and test loads to support full load and factory acceptance testing
  • Machine shop for custom fabricated assemblies and busbar systems
  • Material handling equipment capable of manipulating small devices, to complete packaged control rooms, all tracked by our in-house reporting and ERP system
  • Flexible manufacturing—allows for panel fabrication from either location, or both locations simultaneously
  • WBE (Women’s Business Enterprise) Certified

What makes us different is that in peak times we can balance the manufacturing loads between the two facilities so that we can ensure a fast turnaround time for panel orders regardless of the size.

Brock Solutions’ Electrical Control Panel Fabrication Project Methodology

Brock Solution’ well-defined panel build project methodology can be applied to any project or program regardless of size. Our methodology covers all steps in the project life cycle from initial information gathering to final system acceptance, delivery, and continuous improvement activities. Time is spent upfront with our customers to ensure specific requirements of the project are captured. Checks and balances are in place to ensure these requirements are being met throughout the project life cycle and that continuous feedback on progress is provided.

Below are examples of the typical steps followed and resources involved in panel build projects and outsourcing programs:

Program Management
  • Dedicated Program Manager assigned on all outsourcing programs to regularly interact with the client to ensure program requirements are being met
  •  Resource planning to account for fluctuations in work volumes
  • Identifying areas for standardization in materials and design to reduce cost and promote consistency across the outsourcing program
  • Business development efforts including working with the clients estimating and design teams to support development of estimates and proposals for their end customers
  • Conduct quarterly business reviews held with all stakeholders
Project Management
  • Provide single point of contact for scheduling, progress updates and coordination
  • Work with Materials Management to procure project materials and sub-assemblies
  • Provide interface to Fabrication and Quality teams
  • Manage subcontractors and 3rd party suppliers
  • Forecast capacity requirements and schedule work in appropriate locations to meet customer needs
Information Gathering
  • Determine requirements of the project/program including scope, delivery, quality and financial goals
Value Engineering
  • Determine alternate design and materials to support product enhancements and cost reduction
Project/Program Costing
Pre-Fabrication
  • Develop fabrication processes specific to application (i.e. break system into subassemblies for high volume builds)
  • Panel Certification to CSA and UL
  • Setup facility according to project requirements (i.e. process flow, assembly line, access to special equipment and tooling etc.)
Fabrication
  • Fabricate first article
  • Fabricate sub-assemblies
  • Integrate 3rd party content
  • Final assembly and wiring of system while documenting all fabrication steps
Quality
  • Apply standard testing procedure or develop custom testing and quality checks specific to program
  • In process checks/testing
  • First article validation and acceptance
  • Final testing to agreed upon quality standard
  • Full load testing and Factory Acceptance Testing (FAT) as required
  • Final product certification (CSA, UL, CE)
  • Complete documentation and traceability of product and quality process
Shipping and Logistics
  • Coordination of incoming goods from global suppliers
  • Leverage existing logistics network to establish best fit for application
  • Final shipment to customer location including customs and brokerage activities
Continuous Improvement
  • Project post-mortems and lessons learned involving all stakeholders
All activities are a collaborative effort with regular interaction and input from our customers. Our panel build project methodology is proven and ensures that projects are delivered on time and within budget, irrespective of their size, scope, and complexity.

Outsourcing & Contract Manufacturing

Companies that manufacture their own panels often struggle with consistency, quality, competitiveness and the unsettling fluctuations in work volume and resources when it is not their core focus.

Panel outsourcing and contract manufacturing are a core competency of Brock. Brock is experienced serving as a contract manufacturer supporting the long-term needs of large global companies across many industries. All outsourcing and contract manufacturing programs have a dedicated Program Manager assigned to regularly interact with the client including quarterly business reviews held with all stakeholders to ensure program requirements are being met. A key focus of the Program Manager is to look beyond the day to day activities and plan for the future. Typical activities include planning for fluctuations in work volumes and identifying opportunities to standardize design, material, quality and approach across our customer’s organization while maintaining flexibility to accommodate unique situations.

Our goal is to develop long term partnerships that are mutually beneficial and meets the business needs of our customers growing organizations while providing a significant return on investment as quickly as possible.