Sun Transformer Recertified to ISO 9001:2008
During November of every year, we here at Sun Transformer start feeling a little festive. An excitement fills the air, and workers throughout the plant await the arrival of a special visitor.
Yes, that’s right. It’s time for a visit from our independent auditor to verify that our quality processes continue to meet ISO standards.
Since 1999, Sun Transformer has been certified every three years to ISO standards. Each May and November we welcome our auditor back for a surveillance visit to ensure that the various aspects of our manufacturing process are being performed properly. This year marks the second straight year that we’ve met the updated ISO 9001:2008 standard.
I recently visited with Angie Calkin, who serves as Vice President of Operations, to ask her about the importance of meeting ISO standards.
Q: Sun Transformer has met ISO 9001 standards since 1999 and has been recertified every three years since then. Why is this done?
A: We have some customers who either require it or would want to do their own process audits at the plant if we weren’t certified. But it’s more than that. We have other customers who don’t require that we meet ISO standards but still benefit because we do.
Q: How so?
A: When we implemented our quality system, we saw a steady decrease in both customer concerns and customer returns, and that applied to all of our customers because the same process is followed for every product and in every phase of manufacturing.
“Before we start full production on an order, we test two or three units to make sure they meet exact customer specifications. After a unit passes pre-testing, we can produce the full order. That way, we don’t complete production on an order then find out we missed a slight detail.”
Q: Have the quality processes helped make Sun Transformer more efficient?
A: The ISO standards are intended to improve overall quality rather than reducing manufacturing time, but we do spend less time correcting production errors so we can factor in that aspect of it.
Q: Are there other benefits?
A: In cases where we submit our products for consideration on large projects, the customer will have a list of standards we must meet before we can be considered. For the most part, we can show the customer that we already meet their requirements—and have for many years—because their requirements are already part of our ISO quality processes.
Next, I spoke with Brad Cross, president of Sun Transformer, to get his thoughts on the whole quality process.
Q: Having recently completed another ISO recertification, what are your thoughts about the importance of this event?
A: The first thing that comes to mind is that it’s a real tribute to the diligent work of our Quality Manager Angie Calkin and the rest of the staff who have taken our quality processes very seriously. They’ve recognized the importance of our quality procedures and the resulting benefits to our customers.
Q: What types of customer benefits have you noticed?
A: One big improvement that we made while implementing this process was pre-testing. Before we start full production on an order, we test two or three units to make sure they meet exact customer specifications. After a unit passes pre-testing, we can produce the full order. That way, we don’t complete production on an order then find out we missed a slight detail.
Q: Is this testing done for both electrical and mechanical specs?
A: Yes. Of course, we also perform 100 percent testing on all of our parts after production is complete—and pre-testing really helps decrease the number of errors we find at that point. A huge part of our quality improvement is the longevity and experience of our staff. If you’ve got people like Randy Kaufman [Senior Test Technician at Sun Transformer], who knows exactly what to expect with each part, they’re going to recognize when something isn’t quite right, and they make sure the issue is corrected before we ship them out.
Sun Transformer Increases Testing Capability
In an effort to further increase testing volume—and to ensure that all manufactured components may be tested to NEMA standards—Sun Transformer has recently added a Despatch Ecosphere environmental chamber to it’s array of test equipment.
According to Electronics Technician Steve Lescalleet, utilizing this type of equipment is an essential part of the electronics manufacturing process.
“The environmental chambers put our products through temperature extremes that they’ll probably never see out in the field,” Lescalleet says. “If the units can work properly through this type of testing, there’s no question in our minds about whether they can withstand real-life extremes.”
Depending on customer requirements, the environmental testing performed by Sun Transformer may include various tests that cover operating voltage, high and low temperatures, humidity, vibration, and shock (as defined by NEMA TS2 standards).
“The environmental chambers put our products through temperature extremes that they’ll probably never see out in the field. If the units can work properly through this type of testing, there’s no question in our minds about whether they can withstand real-life extremes.”
Lescalleet points out two primary objectives when it comes to performing these demanding environmental tests.
“The first objective is to find weaknesses in product design, and we do this kind of testing on prototypes so we can eliminate these weaknesses before we begin full-scale production. The second objective is find weak points in our assembly process so our production methods can be continually improved.”
So which of the many environmental tests performed by Sun Transformer is the most demanding for electronics components?
“The tests related to low-temperature limits present the biggest challenge, no doubt,” says Lescalleet. “When a unit has been subjected to our low-temperature tests, they’ve essentially been through a really, really bad winter. And If a unit doesn’t pass the required tests, it doesn’t leave the plant.”
Vaughn Celebrates 20 Years with Sun Transformer
Design Engineer Les Vaughn recently celebrated his 20th anniversary with Sun Transformer. In 1988, Les joined Sun Transformer and worked primarily in designing and building the test fixtures that were used to verify proper performance before units were sent to customers.
Prior to joining the company, Les had completed a degree in electronics and had worked as a radio broadcast engineer, as well an on-air personality. This experience and training proved beneficial as he took on a greater and greater role in the design of circuit layouts for customers.
Les’ current job responsibilities include working with customers to define requirements—as well as building and testing prototypes to meet these requirements. He also designs transformer power supplies and even avails himself when needed for difficult production equipment repairs.
When asked where he gains the most satisfaction from his job, Les doesn’t hesitate.
“When I talk to a customer and they have just a basic idea of a requirement, and I can build a part that they need and can use. That’s when I get the most satisfaction.”
Congratulations Les!
Linda Shaw Celebrates 20 Years with Sun Transformer
Linda Shaw recently reached the 20-year milestone with Sun Transformer. In 1988, Linda began working at Sun Transformer as part of the Production Team. After five years in this position, she was promoted to Production Team Leader, where she currently serves.
Linda’s responsibilities include assigning job tasks, supervising production procedures and quality, measuring build times, and training production personnel. Linda also assembles transformers and offers a wealth of knowledge about proper production methods for all types of Sun Transformer products.
Linda has received extensive ISO 9001:2000 training, and she works closely with the Design Engineers in creating and testing prototypes. She has also worked with UL inspectors during the approval process for Sun Transformer products.
Congratulations Linda!
Lescalleet Joins Sun Transformer As Electronics Technician
Steve Lescalleet has joined Sun Transformer as an Electronic Technician. In this role, Steve is responsible for the proper assembly and testing of several Sun Transformer products.
Steve holds a degree in Aviation Elecronics from Southern Illinois University as well as FCC and FAA certifications. He has over 20 years of experience in electronics, including work in avionics for American Airlines (TWA). His interest include general aviation (private pilot license), electric cars, and solar power. Steve is a welcome addition to the Sun Transformer team.
Kolts Joins Sun Transformer as Communications Manager
Scott Kolts has joined Sun Transformer as Communications Manager. In this role, Scott is primarily responsible for developing product manuals, company marketing material, and web sites. Scott has ten years of experience in technical writing and marketing, and he is a welcome addition to the Sun Transformer team.
Sun Transformer Celebrates 20 Years of Excellence
Sun Transformer has been supplying customers with the best quality in printed circuit assemblies since 1986. We appreciate both the customers who have been with us since the beginning and those who may have just discovered Sun Transformer.
Sun Transformer Preparing for ROHS/WEEE Compliance
Sun Transformer is preparing to meet the schedule for compliance mandated by Europe’s RoHS/WEEE (lead free) directives on effected products. If you need information about the compliance schedule or requirements for items you purchase from Sun Transformer, please contact Les Vaughn at sales@suntransformer.com or 618-643-2555.
Sun Transformer Named “Small Business of the Year”
Sun Transformer was among several businesses and individuals receiving recognition at the annual Legislative Recognition Breakfast held June 7, 2004 at Southeastern Illinois College. The event was held in conjunction with National Small Business Week.
Tammy Weston, director of Southeastern Illinois Regional Planning and Development Commission presented the award. Brad Cross accepted the award on the behalf of Sun Transformer.
Copper Prices Continue to Rise
January 1, 2004 – Copper, an essential component of virtually all electronic assemblies continues to climb the cost ladder.
Detailed historical charts of copper market prices can be found on the internet at http://futures.tradingcharts.com/chart/CP.
The “base price” or the cost magnet wire suppliers pass along for the copper content in wire is typically $0.35 higher than the “High Grade Copper” price shown in most market charts.