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Three Million Hours of Reliability
Pioneer Magnetics, Inc. (PMI) has shipped over 700,000 of standard, mods and custom power supplies ranging from 500 to over in just the last 40 of our 50-year history. Recognized as an , the reliability of our units is confirmed by repeated orders from major customers worldwide. The Demonstrated Mean Time Between Failure (DMTBF) for a typical PMI power supply today may range between 1 and 3 million hours, depending on product type and quantity shipped.
Registered to ISO Standards
Using tools such as statistical process control, Pioneer Magnetics’ testing procedures facilitate the validation and control of assembly activities. PMI uses a zero defect approach in the integration of its products. PMI has the ability to design, document, monitor, implement, control, and support changes throughout the manufacturing process without impact on final product quality. PMI’s ISO registration signifies our commitment to quality.
Certifications
In addition to rigid customer specifications, PMI’s certifications by industry boards include:
Why is this important? This means to the end user that, after a power supply’s many years of excellent service, the PMI engineers who actually designed the product can do the following:
- Support the customer service process.
- Provide detailed and accurate failure analysis.
- Assist customer when there has been a system failure.
Quality Control
Quality Control is PMI’s highest priority. Our system is modeled after ISO standards and BABT guidelines. Our entire company is continually audited by many of the largest manufacturers of computer systems, telecommunications, process controls, and medical equipment. This means that consistent quality service and full tracking capabilities are essential elements of our quality program.
The following are some of the processes PMI employs to correctly and efficiently solve a problem:
- ISO Procedures
- Class III Workmanship Standards (Class III – PMI uses IPC workmanship standards, ensuring that all products are shipped at the highest quality level.)
- TQM Principles (Total Quality Management (TQM) is a business management strategy aimed at embedding awareness of quality in all organizational processes. TQM has been widely used in manufacturing, education, call centers, government and service industries, as well as NASA space and science programs. TQM is composed of three paradigms:
- Total: Involving the entire organization, supply chain and/or product life cycle
- Quality: With its usual definitions, with all its complexities [1] ()
- Management: the system of managing with steps like Plan, Organize, Control, Lead, Staff, provisioning and organizing.
As defined by the International Organization for Standardization (ISO):
“TQM is a management approach for an organization, centered on quality, based on the participation of all its members and aiming at long-term success through customer satisfaction and benefits to all members of the organization and to society.” ISO 8402:1994
- Multiple ESD Disciplines (The basics of electrostatic charge, discharge, types of failures, ESD events and device sensitivity may be summarized as follows:
- Virtually all materials, even conductors, can be triboelectrically charged.
- The level of charge is affected by material type, speed of contact and separation, humidity and several other factors.
- Electrostatic discharge can create catastrophic or latent failures in electronic components.
- Electrostatic discharge can occur throughout the manufacturing, test, shipping, handling or operational processes.
- Component damage can occur as the result of a discharge from the component as well as a direct discharge to the component.
- Components vary significantly in their sensitivity to ESD.
Basic Principles of Static Control
- Design In Immunity. The first principle is to design products and assemblies to be as immune as is reasonable from the effects of ESD.
- Eliminate and Reduce Generation. The second principle of control is to eliminate or reduce the generation and accumulation of electrostatic charge in the first place.
- Dissipate and Neutralize. The third principle is to safely dissipate or neutralize those electrostatic charges that do occur. Proper grounding and the use of conductive or dissipative materials play major roles.
- Protect Products. The final ESD control principle is to prevent discharges that do occur from reaching susceptible parts and assemblies.
Elements of an Effective ESD Control Program
- Establish an ESD Coordinator and ESD Teams.
- Identify Losses
- Evaluate The Facility, Processes and Needs
- Identify ESD-Sensitive Items
- Build Justification for the Program
- Get the Support of Top Management
- Establish and Implement Procedures and Specifications
- Train Personnel
- Review, Audit, Analyze, Report, Feedback, Improve
- MIL-Spec-type Corporate Culture (Please “Google” for typical “MIL-Spec” requirements)
- Lean Concepts
- Specify what creates value from the customers perspective
- Identify all the steps along the process chain
- Make those processes flow
- Make only what is pulled by the customer
- Strive for perfection by continually removing wastes
- A "Can Do" Attitude Pioneer Magnetics has a 50-year history of “Yes, we can – yes, we will” attitude. Working around the clock, weekends and anything else that may be required to meet a customer’s needs is part of the PMI culture.
State-of-the-Art-Test Equipment
Our test and service facilities have all the equipment necessary to functionally test at the board and finished product under full load. Test capabilities include (in part), functional testers, auto-testers, and thermal burn-in chambers. We typically burn in units for 48 hours. All serviced units receive the same Acceptance Test Procedure (ATP) as new units.
Qualified Technicians
All PMI technicians are fully trained with years of experience in electronics repair, and possess the skills and resources necessary to ensure professional and exemplary service. In addition, PMI’s engineering department is always accessible for supplementary support.
Process Tracking
PMI’s facility is fully computerized to ensure the most accurate and reliable handling of your product throughout the refurbishment process. A computerized tracking system monitors the unit from the issuance of an RMA through receiving, testing, servicing and shipping. A record of the servicing is entered into the PMI database that resides in PMI’s Reliability Engineering Department.
Parts Inventory
PMI maintains an extensive inventory of components ensuring that the turnaround to repair your power supplies occurs in a timely manner. A state-of-the-art MRP system monitors long lead-time, unique and hard-to-get materials.
Modification Process
If possible, PMI modifies older units to the latest PMI configuration level.
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