WHAT WE DO
Define | Engineer | Realize
PCH Lime Lab is a division of custom product solutions company PCH. We define, engineer and realize compelling products for companies who are passionate about design, brand and the consumer experience.
We engineer products — based on your unique requirements — that reliably meet stated performance objectives when produced at scale. Our experienced team of mechanical, electrical, and software engineers work side by side with your team and your partners to create products that reflect your goals. Through creative thinking, engineering analysis, and effective prototyping, your vision is transformed into a product that personifies your brand.
Attention to Detail at Every Step
We have a 7,000-square-foot, in-house prototyping facility featuring state-of-the-art equipment and experienced shop personnel. Our prototyping lab means we can iterate quickly and get new builds to you faster.
PCH Lime Lab works with the best industrial design studios in the world as well as Fortune 500 companies and innovative startups to get quality products to market faster.
Our association with PCH means we have 20 years of experience sourcing and manufacturing products at scale. We design for manufacturing (DFM) and for assembly (DFA) from the very beginning, uncovering potential complications earlier, and driving better solutions from the start.
We identify key features and technical risks and devise solutions. We work closely with your industrial design partner to protect and carry out the design details, brand attributes and consumer experience.
We examine the product inspiration, core value proposition and available technical resources. We work with you to define clearly the project objectives, to understand the top execution risks, to map out hard deliverables, and to set the overall schedule and budget expectations.
We examine the competitive landscape and assess the performance of market leading products. We nail down the hard product requirements and include a plan to evaluate product performance. In parallel, we work with your ID team to fabricate product mock-ups for high level UX evaluation.
We create a complete and coherent product architecture that prioritizes key performance points and COGS target. To inform the design direction we perform engineering analyses and calculations. To evaluate high risk features, we kick off breadboards. Working with your ID team we reconcile the industrial design vision with electro-mechanical reality.
The detailed design and iterative build work is intended to prove out the product fit, function, and performance limits prior to the validation stages with your manufacturing partner. Our fully featured, production-intent prototypes demonstrate the product functionality, and instill confidence that the aggregate design decisions were valid.
The goal of this build is to demonstrate the high-level function of all feature. Mechanical, electrical and firmware engineering, and program management come together for the first integrated build, showcasing the best thinking from each discipline. We evaluate our builds from a design-for-assembly standpoint, manually stepping through each assembly step to simulate the production line. Integration risks are exposed and solutions identified.
As an evolution of the B1 design, the B2 build is intended to show that design changes solved any issues seen in B1. Prototypes are tested against concrete specifications and some may be tested to failure where appropriate to understand the limits of performance. The gap between the B2 design and production design should be minimized to ensure build learnings translate to real world performance.
For highly complex products where the integration risk is large or the performance goals are extreme, a B3 may be added to solve technical issues and build confidence that the design is ready to be hard-tooled and that long-lead components and assemblies should be ordered.
We conduct a series of organized builds in the production manufacturing setting – working with component suppliers, subassembly fabricators and contract manufacturers – to demonstrate that the design solution performs similar to (if not better than) the prototypes from the previous phase. Leveraging production tooling and scalable assembly processes, large lot sizes can be efficiently produced to allow the development team to study product quality, performance reliability and supply chain scalability.
EVT (Engineering Validation Test) is where the rubber meets the road. The goal is to confirm that Mass Production (MP) tooled components perform similarly to or better than the prototypes from the previous build development. Using the final assembly production facility, engineers assemble enough units to assess all product performance points as well as to assess product reliability and durability. Small design changes are expected in this phase. The manufacturing team will also develop the production assembly process, including any in-line quality check points that are needed to address process variation.
DVT (Development Validation Test) is a natural evolution of the pre-production effort. Production fixtures, jigs and other assembly aides are set in place on the production line to ensure consistency while maximizing speed and yield. Tooled components and subassemblies are further refined to optimize cosmetics and overall quality. In addition to more reliability testing, some units from this build will be dedicated for regulatory and certification testing to ensure compliance.
PVT (Production Validation Test) is the final gate before releasing your product into the wild. The MFG team will build a large quantity of units to “stress test” their entire process and expose operational issues. We confirm capacity, cycle time and line yield. Units from this build are earmarked for a variety of tests including reliability testing, user testing and for pre-market release such as marketing and placement. Packaging, accessories and kitting details are dialed in as these units represent the final salable product. Some units are pushed into the sales channel to confirm distribution flow and identify bottlenecks.
At this stage, product is considered to be ready for mass production based on results of the PVT build.
A team will be assigned to the project and will focus on day-to-day management of the FATP and sub-suppliers, including:
Quality control and process analysis:
• Monitor supply chain yields and implement continuous improvement plans
• Help analyzing customer returns and corrective actions
• Change Order management
• Assess sustainability of process choices
• Assess risk and impact of initial supply chain reports
• Best practice benchmarking for manufacturing
Supply Chain Optimization:
• Provide any requested KPIs through daily, weekly, monthly and quarterly reports
• Perform business reviews with key suppliers (QBR)
• Conduct regular audits of the supply chain for financial and CSR standards
Continuous cost reduction programs, including price negotiations, alternative suppliers and VA/VE projects
PCH POSTPONEMENT SERVICES
PCH can manage the kitting and fulfillment of your product through our facilities in the Shenzhen Free Trade Zone managing the pack out production line to optimize efficiencies and ensure every package is 100% perfect.
We will manage the supply base so that finished product configurations are postponed until the final touch point.
PCH can also manage inventory and ensure it is aligned to your forecast, as well as work with your planning team to manage the product life-cycle and ensure that excess inventory is minimized.
WHO WE ARE
Meet Our Team
We are an open minded, diverse and collaborative group where team members bring unique ideas, experiences and talents to each project. Everyone has a voice and everyone is respected. We explore together and solve difficult problems as a team. We enjoy the rigors of engineering, and the confidence of our clients and partners.
We are fast-paced and passionate, and we often have tight deadlines, but we respect life-work balance, and share expectations together. We build trusted and strong relationships with our peers, design studios and clients because we deliver.
“We love challenges because they push us to do our best work and to keep learning and growing.”
— Andre Yousefi
We love a challenge because it’s what pushes us to do our best work and to keep learning and growing. We are curious and find simple and elegant solutions that get our clients to market faster, with better and more reliable products. For us, it’s all about shipping products, making our clients successful, and seeing our work in the world.
And, if you like having fun. So do we. Whether it’s taking time out for lunch together, getting out for a run with the running club, flipping burgers at our monthly BBQs, dressing up for our Halloween costume party, celebrating birthdays, or making a dish for Thanksgiving, we celebrate together and take time out to enjoy friendship and camaraderie.
Director, Business Development
Alex has been taking products from concept to consumer across multiple industries for over 25 years. After honing his skills in product development, marketing, branding and sales for action-sport brands like Bonfire, Burton, Adidas and Salomon, he started working closely with technology companies such as Griffin, Astro Gaming, Speck and Mophie.
He joined PCH Lime Lab in 2013.
Vice President and Co-founder PCH Lime Lab
Andre has 20 years of experience working with consumer products companies. He is passionate about shipping products, and building a culture with deep appreciation for industrial design.
Prior to PCH Lime Lab, Andre managed product development at WET Design. He began his career at IDEO in London, where he was design director, and held design engineering and development roles there and internationally. Andre received his degree in Design Model Making from Hertfordshire University and a B/Tech Ordinary National Diploma in Three-Dimensional Design awarded by Sheffield Granville College.
Carlos Martin Gascon
Director, Manufacturing and Integration
Carlos splits his time between Shenzhen, China and SF. He spent eight years in China where he held management positions on both product development and manufacturing side. Carlos has brought many products to market. He identifies the right manufacturing partner, and sets up the supply chain for products. He is well-versed in a variety of industries — from refrigeration and air conditioning systems, to home appliances, to consumer electronics. Carlos ensures product design is ready for manufacturing from the start of each project, mitigating risks before tool release.
Director, Prototyping Lab
As PCH Lime Lab’s Director of prototyping, Chris Iverson oversees The PCH Innovation Lab, and aids in all aspects of prototyping. With extreme focus on precision and attention to detail, Chris brings 36 years of product development prototyping experience to PCH. Classically trained as a journeyman prototype machinist at NASA, he brings many years of experience in the manufacturing of complex laser, medical and consumer-based products. Chris is a perfectionist who loves what he does.
Christian is the GM of PCH Lime Lab and is responsible for day-to-day operations and for delivering results at the highest level of customer satisfaction.
Christian brings over 20 years of product development, creative leadership and technical skill and experience to his role, and has worked in a creative and industrial design capacity with such companies as John Deere, Nike, Thales/AirBus, Motorola, Kodak, Tivo, Disney, Thales/Magellan, Logitech and Maxtor.
Before joining PCH in 2014, Christian held senior roles at Frog Design, including creative director of industrial design and GM of the West Coast and creative studios in Europe and Asia.
VP, Communications, PCH
Claudia has over 15 years of experience in marketing and public relations. She has led the communications role, and held several VP and director-level roles at companies, including One Kings Lane, Cisco, ABC Television Network, and Bozell Public Relations. Claudia has developed many campaigns to support new consumer product launches.
Graham has a passion for design and product packaging. He has over 25 years of experience working with a variety of packaging types that meet marketing, retail, supply chain, and quality control goals. A journeyman educated in packaging structural design, mechanical engineering and manufacturing and finishing, Graham creates unique and highly functional and sustainable packaging concepts for PCH clients. He lives with his family in Danville, California.
Director, New Business Development
Jessica is a seasoned technical account manager. An engineer by training, with a BS in Electrical Engineering from UC Santa Barbara, and an MS in Engineering Management from Tufts University, she has successfully managed engineering projects and teams, and helped clients bring products to market. Before joining PCH Lime Lab she was at Hamamatsu Corp, and earlier at Raytheon.
Principal, Business Development
Kerrigan has been actively involved in emerging technology and e-commerce for over 15 years where he led successful teams in commercial operations, supply chain, social media, content and customer experience. Prior to joining PCH Lime Lab, he was at Thync, a startup integrating wearable tech with neuroscience, and earlier at Leap Motion, a startup developing motion-control and sensing tech. He has experience in the automotive, consumer electronics and e-commerce sectors.
Co-Founder PCH Lime Lab, Vice President Highway 1
Kurt has spent the past 20 years designing, engineering and shipping iconic products. His experience in consumer electronics includes core technology development on the iPod and first iPhone; launching Astro Gaming’s line of high- end gaming accessories; and developing digital photo sharing tools at his first engineering consultancy. Kurt developed furniture for Design within Reach and Coalesse, a Steelcase Co., and athletic gear at IDEO.
Kurt received his BS in Mechanical Engineering from Northwestern, and an MS in Product Design from Stanford. He recently joined the Board at SFMade.
Director, Engineering Program Management
With over 20 years of engineering development and program management experience, Maneesh is Director of Engineering Program Management. He most recently spent more than five years at Tesla Motors as a production and engineering program manager. Prior, Maneesh was at BAE Systems for 14 years as a mechanical engineer, software developer, and engineering & program manager on several R&D programs. Maneesh has an undergraduate degree from the University of Michigan and a master’s degree from Stanford — both in mechanical engineering. He spends his free time with his wife and two young sons.
HR Business Partner
Melissa loves to help individual contributors and managers grow and realize their full potential. She also helps bring teams together to build cross-functional relationships and mentorship opportunities. She holds a Bachelor of Science degree in Anthropology from UC Santa Cruz. She is a frequent traveler who immerses herself in new cultural experiences. Melissa rides her bike to work and runs weekly with the PCH Running Club. In her spare time, she can be found enjoying the outdoors.
Director, Mechanical Design Engineering
Philipe has spent 16 years engineering products in medical devices, consumer electronics, sporting goods and apparel. After graduating from Stanford with a double degree in mechanical engineering and product design, Philipe spent six years designing automated blood vessel stapling tools for cardiac surgery. He holds multiple patents and learned product development via the rigors of the FDA-regulated design control system. Philipe worked at Apple where he designed the chemically-strengthened iPhone glass cover, touch module and various enclosure components. He has designed parts for injection molding, metal stamping, metal injection molding and CNC machining.
Robert has 12 years of experience managing finance for companies within professional service industries. Prior to joining PCH Lime Lab he spent nine years in the public relations and advertising industries working for Ogilvy & Mather and Draft FCB. Robert earned his undergraduate degree in economics at the University of California, Davis. Robert loves to spend his free time on the golf course and taking drives along the Pacific Coast Highway.
Director, Systems Architecture
Vijay is a passionate, self-driven, high-impact engineering lead with a successful track record of taking products from concept to manufacturing to consumers. He has extensive experience in systems design for consumer electronics products such as mobile phones and wearable connected IoT product. Vijay heads up electrical, firmware and RF engineering teams. He has a bachelors of science degree from the University of Madras in electronics and communications and a masters degree in electrical engineering from the University of Southern California.