Megger

Agile hardware development secures resilience in Megger’s global product portfolio

Megger, a global leader in electrical measurement and monitoring, delivers trusted instruments to infrastructure providers worldwide. As the COVID-19 pandemic put pressure on global supply chains, Megger faced increasing difficulty securing continued access to a critical Bluetooth component that was declared end-of-life during the process. Without a viable replacement, their ability to deliver key products was at serious risk.

To solve the immediate challenge, Megger partnered with Mjølner Informatics. Together, they developed a robust and flexible replacement solution that restored product delivery and enhanced Megger’s platform architecture.

The experience sparked deeper insights. Mjølner identified design patterns and cross-disciplinary practices from the project that would later form the foundation of what is now known as the Multi Source Design (MSD) methodology.

Branche:

Manufacturing

Vi leverede:

Softwarekonsulenter, End-to-end projekter

Teknologi:

Embedded user interface development

A critical component becomes a strategic turning point

In the midst of the pandemic, Megger faced a challenge that echoed across the global electronics industry: a vital Bluetooth chip, embedded in 28 variants of their electrical measurement instruments, was suddenly declared end-of-life. With no direct replacement and a global chip shortage in full effect, Megger risked being unable to deliver large portions of its product portfolio.

Instead of opting for a short-term fix, Megger partnered with Mjølner to develop a long-term solution that would eliminate single-point dependencies and future-proof its hardware platform. The collaboration also introduced a new and more flexible approach to hardware development, with a strong focus on long-term resilience.

“We didn’t just need a fix. We needed a new way of thinking, and that’s exactly what Mjølner brought. Their partnership helped us rethink our development process and implement a smarter, more agile approach that made a lasting impact.”

Stephan Sommer, Managing Director at Megger

Designing for change – not just delivery

The development process centered on modularity and iteration. Together with Megger, Mjølner introduced a layered architectural approach in which core components could be redesigned or replaced without impacting the overall system. This gave the team the flexibility to navigate not one, but several unforeseen component changes throughout the course of the project.

An abstraction layer was developed in the firmware to ensure that communication between instrument and Bluetooth module could be adapted across different hardware options. Initial prototyping was carried out using evaluation boards, allowing the team to test functionality and validate changes early and often. As new component constraints emerged, the architecture made it possible to switch microcontrollers and Bluetooth modules with minimal disruption, and even upgrade from Bluetooth Classic to BLE to meet new iOS compatibility requirements.

Throughout this process, hardware and software teams worked in close alignment, supported by a structured approach to synchronization between disciplines. The agile principles from software development were successfully extended to the physical product domain – enabling faster cycles, clearer collaboration, and better outcomes.

A competitive advantage

The benefits of the new approach extended well beyond the engineering teams. For Megger, the project demonstrated how a modular, flexible architecture can significantly increase robustness against future supply chain disruptions. By reducing dependency on single components and enabling rapid adaptation, Megger is now better equipped to maintain delivery and performance even in the face of unexpected challenges.

By embracing modular design and iterative development, Megger significantly reduced its dependency on long-lifecycle components, opening the door to more cost-effective and innovative technology choices. Instead of being limited to components guaranteed for decades, Megger could now select the best options available with the confidence that future substitutions would be both feasible and affordable.

“Thanks to the work we did with Mjølner, we now feel confident that we can continue delivering our products, even if supply chain challenges like this happen again. Their deep understanding of both the technical and business challenges made a real difference.”

– Stephan Sommer, Managing Director at Megger.

Building resilience for the future

Megger’s collaboration with Mjølner was not only a successful response to a pressing supply chain issue, but it also resulted in a more robust and flexible foundation for future product development. The experience demonstrated the value of modular architecture and close cross-diciplinary collaboration, providing Megger with practical tools to respond quickly to unforeseen disruptions.

In an industry where product lifespans are long and global component availability can change overnight, this kind of technical and organizational resilience is essential. The project proved that with the right partners and a flexible design approach, Megger can continue to deliver, even under pressure.

“What mattered most was that Mjølner helped us find a stable, long-term solution under intense pressure. Their ability to navigate complexity and act fast gave us real confidence – not just in the project, but in our ability to handle similar challenges in the future.”

Stephan Sommer, Managing Director at Megger

The client

Megger (www.megger.com) is a leader in electrical measurement and monitoring, globally running for over 130 years. From power generation to the power outlets in your home, Megger products and solutions cover almost every application within the Electrical Supply Industry. 

The company has nine manufacturing sites in locations within Germany, USA, UK and Sweden, its headquarters based in Dover, UK, and has over forty sales offices across the globe. Megger has grown substantially through acquisitions.

Megger has applications in core segments: cable test and diagnostics, monitoring and APM, protection relays and systems, circuit breakers, transformer test and diagnostics, low voltage installations, general electrical testing, and motor and generator testing.  