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Download case study
Download case study
Cutting-edge wireless sensor provides continuous thermal monitoring
Schneider Electric
Smart wireless thermal sensor
Sketch-to-Scale®, Design for Excellence (DfX), Design for Manufacturing (DfM), New Product Introduction, Manufacturing

Business challenge


The Easergy TH110/EMS59440is a self-powered wireless smart thermal sensor that performs continuous monitoring of critical energy management connections such as cable, bus bar and retractable cable breaker connections on-field.


Schneider Electric SE, a French multinational corporation that specializes in energy management, automation solutions needed a partner to help co-develop and build three models of the wireless sensor. They wanted to partner with a team that had experience taking a product from early prototype to manufacturing. They also wanted a quick turnaround, needing a company that could quickly scale up to mass manufacturing.


Flex provided excellent time-to-market and quality.
- Patrick Ville, Purchasing Director, Schneider Electric


Our Sketch-to-Scale® solution, combined with our supply chain management and manufacturing expertise enabled Schneider Electric to bring their product to market at an accelerated pace.



Combining our ability to co-develop and build innovative products in a rapid and cost-efficient manner with our proficiency in scaling up to mass manufacturing, Schneider Electric identified that partnering with us would accelerate their product development and get it to market quickly.


Schneider saw in us a partner who not only brought a strong understanding of the market urgency but also a dedication to working with a team spirit.




We worked with Schneider to get the Easergy TH110/EMS59440 to market by exploring new technologies surrounding connectivity and identifying the right components and materials. We also delivered mechanical integration of software, hardware and tester solutions in fully industrializing the wireless sensors.


By providing engineering support, optimized sensor miniaturization, packaging design, and product development support, we brought the wireless sensor to market within 10 months-- well within time requirements. The wireless sensors are now being manufactured at Flex Batam, Indonesia where 15,000 units will be produced every month as of the start of 2019.

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