The Plitron Process
New transformer designs are developed in our engineering department using a sophisticated, proprietary, computer aided software program. This program presents our designers with several alternative solutions for physical and electrical parameters. Efforts are made to fit the design into our standard manufacturing processes and materials, but when required, engineering, quality, materials, and production cooperate to find new ways to address unique problems. The goal is an optimum design, offering the best value to the customer. Full CAD specifications are supplied with the quotation.
Once we have reached general approval on the specifications and quotation, prototypes are produced. These are prepared by our sample department, under engineering supervision, subject to production’s standard process control and inspection. After extensive testing for conformity to specifications and safety agency requirements, the design is reviewed, and the prototypes are shipped, usually in less than 2 weeks. Customers are encouraged to test the transformer prototype both on the bench, and most importantly, in the end product. Once the customer is satisfied with the prototype, an acceptance form (sent with the prototype) is completed and transmitted back to PLITRON. The prototype acceptance form allows our engineering department to formalize the product documentation required for full production.
Orders are entered and scheduled with the assistance of a full MRP II system, under the control of Customer Service. All materials requirements, capacity loading, planning and invoicing are done with this system. And because Customer Service controls scheduling, customer changes and expedites are handled in the quickest manner possible.
PLITRON is a certified manufacturer of recognized transformers by UL. Our familiarity with safety agency procedures and their personnel allows us to speed new designs through testing and approval. In most cases a new product is covered by our “Family Approval”, and prototypes can be sent with full UL, recognition and listings. 50Hz transformers are labeled with the CE mark. In cases where a new design is not covered, or a special standard is required, we can work directly with the agency to expedite the approval. PLITRON also routinely designs products for international safety agency approvals such as VDE, IEC, SEMCO, DEMCO, and others where required.
Our Production facilities uses the most up-to-date winding equipment available.
Training Because the quality and performance of a toroidal transformer depends so much on the machine/operator interface, our production staff undergo an extensive training program. The program focuses on both the operation of the machine and in-process inspection techniques.
Our buyers, engineering and quality personnel all work together with our vendors to develop a consistent base of quality raw materials used to produce the finished product. We select materials that are listed by the applicable safety agencies. All incoming material is inspected. Complete vendor histories are maintained by the quality assurance department for analysis of supplier performance.
All transformers are 100% tested using calibrated equipment and trained test technicians. Electrical test equipment includes: turns counters, DVMs, oscilloscopes and dielectric strength (hi-pot) testers, and fully automated test stations.
Our QA department, and production personnel all perform in-process inspections. Results of these inspections are used to refine our processes. Data collected is posted as graphs and charts for all to see. Our focus is continual quality improvement. All shipments are final checked and signed-off by QA inspectors. These final checks include: visual and dimensional requirements, electrical test result review, as well as contract fulfillment.