See How Products Are Really Made. Strengthen Supplier Performance.

BLS Manufacturing Audits provide clear, evidence‑led insight into manufacturing capability, performance, and risk. Delivered as part of our Product & Supplier Intelligence offering, they help teams verify manufacturers, maintain oversight, and resolve quality or performance issues with confidence.

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Explore teardown, benchmarking, and audit options, and see what’s included at every level.
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Manufacturing Performance Is Often Assumed — Not Verified

Manufacturing capability and performance play a critical role in product quality, cost, and delivery — yet these factors are often inferred from certifications, introductory audits, or historical performance. Over time, processes change, workloads increase, and standards drift, creating risk that is not immediately visible.
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When manufacturers are not actively monitored, issues can emerge without warning: declining yields, inconsistent quality, missed deliveries, or uncontrolled process changes. By the time problems appear in finished products or customer returns, the cost of resolution is already high.
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Manufacturing Audits address this challenge by providing structured, on‑site insight into how a manufacturer is actually operating today. By assessing processes, controls, and execution in context, BLS helps organisations understand real manufacturing performance — not just stated capability.

3 Steps. From Supplier Intelligence to Better Decisions

1. Define the Objective

Clarify whether the audit is for supplier validation, performance monitoring, or issue resolution.
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2. Audit and Assess

We conduct structured, on‑site assessments focused on evidence and relevance.

3. Act with Confidence

Receive clear findings, risk prioritisation, and recommendations to improve performance and reduce supply‑chain risk.

Trusted by Innovators

“BLS’s teardown and benchmarking gave us a clear edge in our next product launch. Their insights on cost drivers and design choices were invaluable.”
Head of Product, Consumer Electronics Brand
“The supplier audit report from BLS highlighted risks we’d never have spotted. Their recommendations helped us avoid costly delays and improve quality.”
Director of Procurement, Industrial OEM
“We needed to understand why a competitor’s device was outperforming ours. BLS’s reverse engineering and performance testing gave us the answers and a roadmap to catch up.”
VP of Engineering, IoT Startup

Manufacturing Audits

At BLS, Manufacturing Audits are a structured Product & Supplier Intelligence activity designed to verify manufacturing capability, performance, and ongoing suitability.
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Manufacturing Audits
Clarity on factory readiness—without the noise. We provide manufacturing audits with actionable reports and follow‑up reviews, then layer optional assessments to dive into capability, risk, equipment, lines, and documentation—remotely or on‑site.
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  • Audit base: planning & scope, on‑site/remote assessment, findings with prioritized actions, review call.
  • Process capability assessment (Cp/Cpk where data exists) and CTQ mapping.
  • Supply chain risk check (concentration, geo/logistics exposure, single‑source & obsolescence scan).
  • Equipment benchmarking vs. requirements (accuracy, throughput, automation).
  • Production line validation (layout, takt alignment, bottlenecks, volume readiness).
  • Workforce competency assessment and SOP & documentation audit (control, coverage, revisions).
Product Intelligence
Reveal what competitors build—and why. We perform systematic disassembly, capturing high‑res imagery and a step‑by‑step record so you can see construction choices, complexity drivers, and potential cost levers at a glance. Executive summaries make insights shareable with non‑technical stakeholders.
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  • Physical disassembly to sub‑assembly level with controlled teardown procedures and labelling.
  • Studio‑grade imagery (macro/micro, PCBs top/bottom, key ICs, connectors, mechanicals).
  • Step‑by‑step documentation, risks, and annotated visuals.
  • Executive summary with highlights, images, and mechanical process complexity callouts.
  • Key component identification(MCUs, PMICs, RF, sensors, power stages, displays, motors, batteries).
Cost Intelligence
Know what a product should cost—and why. We translate teardown insight into full BoMs, should‑cost models, assembly estimates, and tertiary costs to support negotiation, supplier strategy, and pricing decisions.
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  • Full BoM creation with manufacturer/part numbers, supplier mapping, mBoM (dimensions/weights), PCBA stack‑ups.
  • Component should‑costing at realistic volume tiers (e.g., 10k/100k), including mechanicals.
  • Assembly cost estimation (labor minutes per operation, overhead by region/cell/line norms).
  • Tertiary cost estimation (packaging assumptions, air vs. sea cost bands, accessories).
Quality & Reliability Intelligence
See workmanship standards—and the risks they create. From solder quality and rework indicators to conformal coat and cleanliness, we assess build quality against IPC cues. We can review reliability assumptions and model MTBF/MTTF to anticipate failures before they surface in the field.
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  • Soldering & build quality review (wetting, fillets, residues, tombstoning, skew, lifted pads).
  • Performance‑vs‑spec checks (when paired with testing modules) to validate claims.
  • Reliability reviews of HALT/HASS data and likely failure modes (where provided).
  • Reliability prediction (part‑count/stress‑based MTBF/MTTF, environment profiles, risk register).
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Features

Why Partner With Us?

Full-Spectrum Intelligence: From teardown and cost modelling to supplier audits and reliability, we cover every angle, no blind spots.
Engineer-Led, Evidence-Based: Real engineers, real analysis. Every finding is backed by data, images, and clear documentation.
Actionable Recommendations: We don’t just deliver data, we provide practical steps to improve cost, quality, and performance.
Flexible, Modular Packages: Build your own service bundle or choose from set options, tailored to your product, budget, and timeline.
Trusted, Independent Partner: 100% objective, with no conflicts of interest. Our only goal is your technical and commercial success.

Resources and Insights

A technician solders wires onto a circuit board inside an open device.

How Teardown Analysis Drives Smarter Product Design

See how BLS transforms teardown findings into actionable business strategies. Learn how product insights drive smarter decisions in product development, sourcing, and market positioning for consumer electronics companies.

Read the Article

Product & Supplier Intelligence Services Menu

Not completely sure what kind of help you need? Request a copy of our Services Menu which provides a visual comparison of our packages, features, and pricing.

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Sample Report

See an example Product Intelligence report.

Download Sample Report

“Product and supplier intelligence evaluates rival products, revealing strengths, weaknesses, market position and IP risks. It helps businesses identify opportunities, pricing strategies and potential challenges for market entry."

James Yorkshades
Director

Frequently asked questions

Everything you need to know about the support we provide.
What types of products do you analyse?
We work with electronics, IoT, consumer devices, industrial products, and more.
How do you deliver your findings?
You’ll receive a detailed report with high-res images, benchmarking data, and clear recommendations, plus a review call to discu
Can I customise the service package?
Yes. Choose from teardown, cost modelling, supplier audits, and more. Build your own bundle or select a set option.
Do you offer on-site audits?
Absolutely. Our team can visit your suppliers or manufacturing sites for in-person assessments.
How fast can you deliver results?
Turnaround depends on scope, but teardowns typically take 5–10 days; audits and benchmarking can be scheduled to meet your deadlines.
What types of products can you analyse?
We support small, medium, and large electronics and electromechanical products—from wearables to smart home devices to industrial handheld tools.
Do you need physical samples?
Yes. We typically require a minimum of two units for teardown work. We can also purchase units on your behalf if required.
How long does the process take?
Turnaround times vary based on product size and selected modules but typically range from 5–20 working days.
Can you benchmark my product against competitors?
Yes. We provide feature benchmarking, performance testing, teardown comparisons, and cost comparisons where possible.
Can you provide should cost models for components and assemblies?
Absolutely. Our cost modelling includes component level costing, assembly labour estimation, overhead estimation, and packaging/shipping cost ranges.
Can you reverse engineer complex electronics?
Yes. We offer circuit tracing, function mapping, firmware extraction (if accessible), and internal imaging (X ray/CT) as required.
What if my supplier doesn’t allow audits?
We can conduct remote manufacturing audits, review documentation, or run a supplier risk assessment based on publicly available and provided data.
Do you work with regulated products (ATEX, IECEx, Medical)?
Yes—with the right tier or modules. Some regulated sectors require specific eligibility and additional documentation, which we support under specific packages.
Do you provide full BoMs?
Yes. Our BoM includes component identifiers and likely suppliers where this can be established.
Can you help with redesign or engineering changes?
We provide detailed redesign recommendations (cost, performance, reliability focused). Full engineering execution is out of scope but can be referred.
How do the IP Verification and Claim Chart modules work?
We map actual product functions, components, measurements, or behaviours against provided patent claims to determine where evidence of use may exist. All findings are technically grounded and supported by imagery, trace data, or teardown evidence, without providing legal infringement opinions.
What is included in a BLS manufacturing audit?
A manufacturing audit evaluates key areas of your production site, such as CSR, HSE, ESD controls, quality systems, documentation, workforce competency, process capability, and production line readiness. You receive a structured audit report with findings, evidence, and prioritised recommendations.
Do you offer both on site and remote audits?
Yes.
• Remote audits are suitable for early-stage assessments, documentation checks, and suppliers unwilling to grant immediate access.
• On site audits (available as an upgrade) provide deeper insight into practices, process discipline, equipment, traceability, and real world operations.
What size or type of facility can you audit?
We audit small, medium, and large product manufacturing facilities, including consumer electronics, electromechanical products, and industrial handheld assemblies. Oversized products or multi site audits can also be supported via custom scoping.
What documents or information do you need before the audit begins?
We typically request:
• Current SOPs and work instructions
• Quality system documentation
• Training records
• Process flow charts
• Layout diagrams
• Existing certifications (ISO 9001, ISO 14001, etc.)
This allows us to pre scope the audit and streamline the on site or remote visit.
How long does a manufacturing audit take?
A standard audit requires 2–6 days depending on product size and modules selected. On site audits add travel and scheduling time. After the audit, you receive a full report and a follow up review meeting.
What kind of deliverable will I receive?
You receive a detailed audit report including:
• Findings by area (CSR, HSE, ESD, quality systems, supplier controls, etc.)
• Risk ratings (e.g., High, Medium, Low)
• Evidence and photos
• A clear list of recommended corrective actions
• Prioritisation for short, medium, and long term improvements
Can you assess compliance for regulated products (ATEX, IECEx, UKEX)?
Yes—manufacturing audits can include checks specific to regulated sectors. This covers traceability, documentation compliance, special process controls, and areas relevant to regulated products.
Do you implement corrective actions for the factory?
Not directly. BLS identifies issues, provides actionable recommendations, and clarifies risks, but implementation of corrective actions is handled by the manufacturer. We can, however, support follow up reviews or re audits if required.
Can you audit multiple suppliers or facilities?
Absolutely. Many clients use BLS to compare multiple suppliers, validate new partners, or audit multi step supply chains. We can scope multi site audits across different regions.
What if the supplier is unwilling to cooperate?
We offer several alternatives:
• Remote audit using available documentation
• Risk analysis based on publicly available data and supply chain mapping
• Review of product samples combined with indirect capability indicatorsWe can also support you in supplier communications to ease concerns around transparency.
What are the most common issues you uncover in a manufacturing audit?
Frequent findings include:
• Weak ESD practices
• Poor documentation control or outdated SOPs
• Inadequate tooling calibration or equipment capability
• Insufficient operator training
• Lack of traceability for critical components
• CSR/HSE non conformities
• Process instability leading to variable quality
How does a manufacturing audit benefit my business?
Manufacturing audits help you:
• Prevent quality failures before they reach customers
• Reduce warranty and return costs
• Improve supplier reliability
• Identify cost saving opportunities
• Mitigate supply chain and compliance risks
• Gain confidence before scaling production or onboarding a new supplier
Need greater confidence in how a manufacturer is performing?
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