How Colocating R&D Drives Manufacturing Innovation w/ Martin DeBono

The Manufacturing Executive · 1 Feb 2022 · 19m · Episode 86

What this episode covers

Martin DeBono, President at GAF Energy, explains how colocating R&D with manufacturing in their San Jose facility accelerates innovation and aids talent recruitment compared to offshore models. He details the launch of their nailable solar shingle, noting that domestic production allows for faster iteration cycles—reducing time-to-market from nearly a year to roughly 40 days—and builds empathy between engineers and operators. DeBono argues that while overseas manufacturing offers lower direct costs, the hidden expenses of travel, working capital for safety stock, and talent retention make reshoring a superior strategy for competitive advantage in the solar industry.

Other shows on the same ground, closest first.

  • Catalyst · 40m

    Scaling America's domestic solar supply chain

    Scott Moskowitz, VP of market strategy and public affairs at QCells and chair of the Solar Energy Industries Association (SEIA), discusses the challenges and progress of reshoring solar manufacturing to the United States. He explains that while module assembly and polysilicon production have been domesticated, the critical middle stages of wafer and cell manufacturing are only just beginning to scale, with companies like QCells and Hemlock Corning leading the charge. Moskowitz highlights that despite US modules costing roughly 30 cents per watt compared to 7-9 cents globally, high demand driven by data centers and AI load growth has made domestic production economically viable, though achieving global cost competitiveness remains a long-term goal requiring scale and policy continuity.

  • The Amp Hour · 1h 02m

    Solar Cells, SparkFun, TSMC - The Detroit Debunking

    Chris Gammell and Dave Jones discuss SparkFun's new 'pick and place grab bag' program, which sells rejected components from automated assembly lines for $10, noting the trade-off between cost and the time required to sort and test them. They analyze TSMC's announcement of a $500M solar cell manufacturing plant in Mississippi, debating whether low US labor costs and local incentives create a viable inflection point for reshoring manufacturing compared to China. The hosts also critique IEEE's membership fee structure for unemployed engineers, the reliability issues of Compact Fluorescent Lamps (CFLs), and the growing problem of electronic waste recycling overseas.

  • Product Startup · 22m

    140: Local Manufacturing for a New Hardware Invention Idea

    Nigel Southway, author of 'Take Back Manufacturing' and former chair of the Society of Manufacturing Engineers, discusses the strategic shift from offshore to local manufacturing for hardware startups. He argues that when factoring in hidden costs like tariffs, inventory, and logistics, the unit cost difference between onshore and offshore production is often only about 10%, making local production increasingly viable. Southway emphasizes the importance of short-run manufacturing to build feedback loops and reduce risk, while advocating for policy, education, and technology integration to rebuild domestic manufacturing capacity.

  • EMS@C-LEVEL · 8m

    Creative Electron's Global Expansion: Made in USA, Serving the World with Dr. Bill Cardoso

    Dr. Bill Cardoso, CEO of Creative Electron, explains the company's strategic joint venture with Unicomp to create a global enterprise with 1,200 employees and facilities in Hungary, India, Malaysia, and China. He details how the partnership blends Unicomp’s high-volume hardware expertise with Creative Electron’s high-mix software capabilities, while maintaining 'Made in USA' manufacturing for the American market in San Marcos, California. Cardoso outlines the company's shift toward dedicated business units for specific product lines like 3D AXI and parts counters to drive customer-obsessed R&D and grow toward a multi-billion dollar valuation.

  • EMS@C-LEVEL · 8m

    From Garage Startup to EMS Excellence with Out of the Box COO Allison Budvarson

    Allison Budvarson, Co-Founder and COO of Out of the Box Manufacturing, explains how her company evolved from a 2008 garage startup to a 70-employee contract manufacturer serving aerospace and defense clients. She details their hybrid business model, which balances 50% revenue from rapid prototypes with 50% from established local OEM products, supported by AS9100 and ITAR certifications. Budvarson discusses the operational challenges of managing fluid schedules and the strategic decision to reshore production despite higher onshore costs, citing intellectual property safety and collaboration benefits. Finally, she highlights the critical industry-wide talent shortage and her proactive approach to recruiting through high school engagement, apprenticeships, and maintaining gender parity in management.

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