What happens when design, software, and manufacturing live under one roof? I sat down with Clarity Design President & Founder Tom Lupfer to explore how an engineering-first culture turns a factory into a learning system—one that moves faster, reduces errors, and keeps shipping even when supply chains seize. From early PCB roots to a modern EMS shop floor, Tom lays out a playbook where DFM is embedded from day one and inspection data powers continuous improvement.

We dig into the feedback loop that transforms SPI and AOI from checkpoints into engines of process intelligence. With Ko Young’s inspection systems on the line, the team closes the gap between design intent and production reality, sharpening paste control, placement accuracy, and yield. That loop gets even tighter with Python-driven automation, cutting manual entry, speeding NPI, and making the design-to-build handoff nearly automatic. It’s not just about equipment; it’s about choosing strategic partners who back tools with training, demos on real boards, and long-term support.

Resilience takes center stage as Tom describes how his team redesigned most active products during the pandemic to match what was actually purchasable—without missing deliveries. That capability becomes an ongoing value-add through sustaining engineering, cost-out rework, and feature updates across a product’s life. We also unpack why medical devices became a strong niche: documentation rigor, traceability, ISO 13485 discipline, FDA registration for Class II devices, and the advantages of being U.S.-based for regulated customers. Along the way, Tom shares a hiring philosophy that puts engineers directly in front of clients, creating a fast, clear path from requirements to architecture, fixtures, and test.

If you care about modern manufacturing, this conversation delivers practical insight: how to select inspection partners, why software belongs at the core of operations, and what culture it takes to align quality, speed, and cost. Subscribe, share with a colleague who lives in DFM and NPI, and leave a review telling us which idea you’ll try first.

EMS@C-Level is hosted by global inspection leaders Koh Young (https://www.kohyoung.com) and Global Electronics Association (https://www.electronics.org)

You can see video versions of all of the EMS@C-Level pods on our YouTube playlist.