Symmetricom is dedicated to the manufacture of high quality telecommunications products. We are knowledgeable in the latest telecommunications technology, including Global Positioning Systems-based products and voice and data transmission. In addition to the electronics, we also build all the mechanical assemblies to support our products, offering complete solutions to the telecommunications industry.
Our customer contracts and order processing are managed out of our headquarters facility at San Jose, California. All unique specifications or special handling requirements pertinent to a certain customer are documented and on file with our manufacturing facilities to insure complete fulfillment of the customer's requirements.
Our manufacturing facilities are located in San Jose and Santa Rosa, California and Aguadilla, Puerto Rico.
Our San Jose facility is ISO 9001:2000 certified and is dedicated to new product development, prototype, initial production, order processing, scheduling, and customer service.
Our Santa Rosa facility is dedicated to new product development, Proto, Pilot, first production builds, the manufacturing of custom engineered precision Time and Frequency products, order processing, scheduling and customer service.
Our Puerto Rico plant is Symmetricom's main manufacturing facility and is ISO 9001:2000 certified. It has been in operation in Puerto Rico for over 18 years and has recently moved into a newly constructed 86,000 square foot manufacturing facility. We currently employ over 200 trained and certified associates at this facility including electronics technicians, operators, assemblers, associate engineers, and manufacturing engineers.
Capacity
Our main factory location currently utilizes approximately 70 percent of its floor space. Capacity can be increased by adding additional shifts and use of the remaining floor space. In the event that long term capacity needs exceed these arrangements, the manufacturing operations are such that additional capacity can be realized within 4 months by hiring additional employees, duplicating ECO-controlled test equipment, and leasing additional facilities. In addition, high volume products are evaluated for outsourcing. We currently have partnerships with several contract manufacturers.
Material Handling
Goods received are inspected in accordance with the company's quality procedures. Inspection requirements for specific items are defined in controlled work instructions. Goods are stored in locked stockrooms that are ESD controlled.
The manufacturing system utilizes sophisticated software that provides levels of identification from receipt of raw material through to tracking the serial number of the final product in the field. Acceptance stamps, data travelers, and/or test data forms are used in the manufacturing and quality processes. Manufacturing procedures are supplemented by work instructions and are maintained in accordance with the company's Quality System. All factory operations are audited as part of internal quality controls with internal quality audits monthly and external ISO 9000 surveillance audits every six to nine months.
Assembly Process
We have the technology and equipment to assemble both through-hole and SMT products. For through-hole assembly we use multiple auto insertion equipment . For hand assembly we use a continuous flow line for high volume and semi-automatic hand assembly (Royonics) for low volume products.
In the SMT area we have state-of-the-art, highly accurate equipment. The associates working in this area have the knowledge and skills necessary to operate and maintain all of the equipment. We have the capability to assemble fine pitch components up to 12 mils. Key features of our pick and place equipment include the capability to center optically and to carry out electrical verification of resistors, capacitors, diodes and transistors. Together with the standard dimensional verification, the process ensures that all PC boards are assembled with the correct, functioning components accurately positioned. Dimensional and co-planarity verification, combined with the standard vacuum test, ensures that the correct component has been picked and not lost prior to placement contributing to our high quality production. Finally, the optimization features of our equipment provide the fastest possible production speed, whether a single board is being laid out or several boards are being mounted simultaneously.
In addition to the equipment described above, we also have a forced convection reflow oven with 10 independent temperature controlled heating zones, a temperature profiler or super mole, hygrothermograph for humidity recording, paste dimension meter and paste viscosity meter.
Test Processes
Our test processes comply with all the standards of the telecommunications industry to guarantee a high level of quality and reliability in all products shipped. The test process typically includes the following steps:
Initial Test Quick test to remove any assembly process-induced defects. Burn-In This step is used to detect and remove components' infant mortality-related problems. We have the capability to run thermocycle or elevated temperature cycles in all of our products. Panel Test Using the latest instrumentation technology available in the market and dedicated test equipment, real applications are simulated to test our products.
System Test
This is the complement of our test process. In this step, the product is tested in its real working environment. All functions are verified to be working as expected.
To be able to conduct accurate and reliable product testing, our technicians use state-of-the-art instrumentation for testing and for troubleshooting. We use GPS technology to monitor our local primary reference to assure compliance with the established parameters of the telecommunications industry. In addition to the standard instrumentation used in all electronics industries, we use specialized equipment for telecommunications. Some of the instrumentation available in our test process includes spectrum analyzers, curve tracers, Loran signal generators, digitizing signal analyzers, dynamic signal analyzers, data and digital data test units and sets, SONET test sets, communications analyzers and optical power meters.
This equipment, combined with our process and our technicians' product knowledge, allows us to test our boards to specifications and diagnose any failed boards down to the component level. This guarantees our customers that the product will perform as expected upon receipt.
Production Management
Symmetricom's manufacturing operations, including order scheduling processes, are run on Oracle 11i software, which operates with principles of ERP, The Master Production Schedule (MPS) is based on forecasts provided by customers and the sales force, historical ordering information from the past year, as well as actual customer orders in backlog. Manufacturing processes are documented with procedures and/or work instructions.
The company plans production schedules firm two weeks in advance and on a forecast basis at least two quarters in advance. Because backlog and forecasts constantly change, the company has designed flexibility into its planning and scheduling systems and cross-trains personnel between product lines to ensure we are able to meet customer-required delivery dates within our guaranteed time period after receipt of order.
The company has the ability to accept and schedule shipment using verbal, faxed, EDI-transmitted, e-mailed or mailed purchase orders. All orders are input into the system and, for the most part, are scheduled the same day as received. In addition, our staff reviews orders to be certain that system configurations are logical.
Manufacturing Technical Support
Symmetricom factory technical personnel, test technicians and test engineers are skilled people, most with 10 to 15 years experience in the electronics and telecommunications industry. They actively participate in product transfers and test equipment development to facilitate the manufacturing process in Puerto Rico. This participation also allows direct interaction with the product design engineers so that factory personnel obtain a good technical knowledge of product performance, enabling them to react immediately to any problems that may arise later during the assembly or test processes.
All testing is designed by the Test Engineering Design groups located in San Jose and Puerto Rico. Our Test and Manufacturing Engineering group in Puerto Rico supports and sustains the testing functions. Both sites have engineering laboratories to design, build, and duplicate all the test equipment used in the manufacturing area in a timely manner.
Summary
Symmetricom has developed the infrastructure to manufacture high quality products. The teamwork environment and the quality commitment of our personnel guarantee that our products comply with the highest quality standards established by our customers as well as our ISO 9001:2000 registered quality systems. As part of our commitment to our customers, we look to continuously improve and enhance our manufacturing methods and to provide the best quality product at the best cost.
