ECM (Electri-Cord Manufacturing) partners with a provider of customized cooling solutions for the critical infrastructure behind the world’s leading businesses. On this project, ECM applied reverse engineering, production documentation, flexible manufacturing capacity, and in-house quality control to support in-door and in-rack liquid cooling assemblies for AI and data center applications. Industry: Technology / Data Center & AI Infrastructure.

The Challenge

The company’s fast growth exceeded its in-house and local supplier bandwidth. Documentation for its in-door and in-rack cooling assemblies was limited to wiring schematics, leaving no dimensioned drawings or formal work instructions to support rapid, repeatable production at scale.

Fast growth outpaced internal and local supplier capacity

Limited documentation beyond wiring schematics for in-door and in-rack assemblies

Needed to protect delivery commitments and avoid contractor delay penalties

    In-rack liquid cooling assembly for AI infrastructure
    Custom liquid cooling components for data center applications

    The Solution

    ECM stepped in as an engineering and production partner, reverse engineering the existing assemblies and building out the documentation needed to scale manufacturing quickly.

    Reverse engineered assemblies and modeled dimensioned drawings across U.S. and Mexico teams

    Converted drawings into work instructions for rapid production launch

    Opened additional capacity through overtime and split/added shifts

    Automated cut, label, and termination work to stage production ahead of long-lead breakers and switches

    Built 200+ point continuity test boards to reduce human-error risk

    Offered flexible fulfillment: direct ship from ECM Mexico, Laredo FOB, and U.S. stocking for just-in-time delivery

    The Result

    This engineering-led approach helped protect the company’s customer delivery commitments by accelerating throughput inside required lead times and reducing the risk of contractor delay penalties, all while maintaining a close working relationship up through the ownership level.

    Accelerated throughput within required lead times

    Reduced risk of contractor delay penalties

    Established a scalable, well-documented production process for future growth

    Contact Us Today

    Looking for a manufacturing partner who can reverse-engineer complex assemblies and scale production fast? Contact ECM to talk through your project.