COMPLEX ELECTRONIC ASSEMBLIES & SYSTEMS OVERVIEW
Spectralux is a global leader in the design and manufacture of data communication products for aviation, performing some of the most challenging requirements of commercial air transport, business and military aviation. In addition, we offer world-class engineering and manufacturing services to the aerospace industry for products with challenging requirements and high reliability to perform flawlessly in severe environments.
ENGINEERING, MANUFACTURING and REPAIR CAPABILITIES
Enabling rapid prototyping, design/build, and build-to-print
• Engineering Capabilities
• Mechanical Design
• Optical / Photometric
• Test Engineering
Manufacturing Capabilities• Prototyping
• CNC Machining
• Complex Paint Applications
• Laser Etching
• Electronic and Mechanical Assembly
• Automated Test
• Vision Based Inspection Systems
• Photometric Development & Testing, Purchasing, Scheduling, Material Controls
Facilities and Processes• Modern, Well Equipped 31,105 sq. ft. Facility
• Substantial Capacity for Growth
• Complete Component Sourcing, Electronic Assembly, and Testing Capabilities
• Commitment to Lean Manufacturing (Product Build Times Averaging 15 days)
• Over 99.5% On-Time Delivery and Quality Record
• ISO 9100 Certification
Repair Capabilities• FAR Part-145 Approved Repair Station
• EASA Part-145 Approved Maintenance Organization
Planning for success
Spectralux Avionics’ project management team is skilled in the successful management of product development projects.
Successful project management relies on five basic processes.• Initiating
• Monitoring and Controlling
At Spectralux, the Initiating process typically begins with a Statement of Work (SOW) or contract. The Initiating process defines and authorizes the project. If no SOW exists, the Spectralux project management will work with the client to help define the project by developing a Project Charter. Involving the customer during the initiating process is essential to ensure acceptance of deliverables and overall customer satisfaction. A dedicated project manager is assigned at this time and is the customer’s focal point for daily progress on the project.
Next and probably most important is the Planning process. The Spectralux project management team uses the Planning process to plan and manage a successful project. The Planning process is made up of several sub-processes and the result is a comprehensive project management plan. The project management plan contains the results of the following processes:• Project Scope Planning and Definition
• Resource and Activity Estimating
• Schedule and Budget Development
• Risk Management
• Communication Planning
• Quality Assurance Planning
The Executing process is where the work defined in the project management plan is carried out and it involves the coordination of resources and activities in accordance with the plan. The Spectralux project team is developed during this process. The project manager works both internally and externally to direct and manage the work defined in the project management plan.
MONITORING AND CONTROLLING
During the Monitoring and Controlling Process, the Spectralux project manager will observe project execution, identify potential problems and take corrective action as necessary to ensure project success. The benefit is that project performance is observed and measured regularly to identify variation from the project management plan. Any variation from the project management plan, most importantly variations to scope, budget or schedule are immediately addressed and communicated to the customer.
The Closing process is where the project is finished. At Spectralux, initial product delivery alone does not mean the project is complete. The Spectralux project manager is responsible to ensure that all requirements in the project have been met. For example, the Closing process may include collecting and finalizing all paperwork needed for product certification and installation.
Spectralux program managers sharpen and maintain their skills by participating in professional development courses, training and seminars. Planning documents are created in Microsoft Word. Budgets are created and maintained in Microsoft Excel. Schedules are developed and maintained using Microsoft Project.
Design partners from concept through final product realization.
Spectralux engineers are your design partners from product conception through delivery. Our engineering team is comprised of a diverse group of professionals skilled in a wide range of engineering disciplines to provide high reliability avionics product development and human interface design.
Our engineers are skilled in interpreting your requirements and translating them into products. We can incorporate your previous designs into our manufacturing scheme and bring your new concepts to life. All you need is an idea and our engineers will utilize decades of aerospace engineering experience to transform a concept into high reliability and cost-effective products ready for the market. We can work with your pre-existing drawings or help you formulate new products and specifications through co-development with our design teams to define and document your new products.
Utilizing various software tools for design, analysis, and verification; Spectralux engineering strives to develop products that meet or exceed customer expectations and function as intended the first time, every time.
Up front engineering analysis is the foundation of our product integrity and reliability. It also gives us an advantage in that it reduces development cycle times by eliminating the need for design iterations. With our analysis tools, we can simulate damaging environments enabling us to test our products for any specified or foreseeable set of conditions. These simulations give us quick feedback, so we can test many more conditions and configurations than we ever could in a prototype phase. Our analysis tools and expertise allow us to truly employ concurrent engineering and optimize designs for functionality, reliability, and manufacturability.
Our software simulation tools include finite element analysis (FEA), computational fluid dynamics (CFD), reliability analysis, and custom tools developed by our engineering team.
Designing products that utilize the properties of light.
Spectralux optical engineers design products that utilize the properties of light. To do so, they understand and apply the science of optics in substantial detail in order to know what is physically possible. In addition to understanding optical science, Spectralux optical engineers understand what is practical in terms of available technology, materials, costs, design methods, etc. and provides the best solution to your requirements.
Commonly, Spectralux optical designers bring control functionality to pilots during night operations. In addition to general night lighting, our optical design team brings a wealth of experience in Night Vision Imaging Systems (NVIS)/NVG to our products and is well versed in MIL-L-85762 and MIL-STD-3009 requirements.
Utilizing a variety of simulation, analysis, and measurement tools; Spectralux optical engineers can provide precise control of chromaticity, luminance, and NVIS radiance to your products. Our optical design team knows what is necessary to provide products that meet or exceed the requirements SAE-AS7788 (Integrally Illuminated Information Panels), MIL-STD-3009 (Aeronautical Lighting for Night Vision Imaging Systems) and SAE-AS25050 (Colors, Aeronautical Lights and Lighting Equipment).
We specialize in full life-cycle development for custom embedded systems on various processor platforms ranging from 8-bit microcontrollers to 32-bit processors including PowerPC, Coldfire, ARM, HCS12, x86, 8051 and Renesas controllers, as well as DSP and PICs. We have experience with real-time multitasking operating systems (RTOS) such as ATI Nucleus, QNX Neutrino, Green Hills uVelOSity, as well as proprietary operating systems. We are well versed in C, C++, C#, Visual Basic, Perl, and various assembly programming languages.
We have experience developing bootloaders, protocol stacks, device drivers, BSPs, as well as PC based applications using Visual Studio (Microsoft certified).
We develop embedded software in accordance with RTCA DO-178 guidelines. We have completed several projects which have achieved TSO certification with software criticality levels ranging from B to D.
Partnerships for mutual success
We rely on our suppliers to strive for and perform to the same standards we do, 100% on-time delivery and quality.
Our procurement department works closely with our suppliers to keep our customer’s projects on schedule. Communication is key! We keep in close contact with them regarding on-time delivery and product quality and expect them to achieve continuous improvement in both areas.
We prefer our suppliers be ISO 9001 / AS 9100 certified. When evaluating potential suppliers, our quality department considers each supplier’s ability to:• Meet contractual requirements
• Supply product per Spectralux requirements
• Demonstrate appropriate process controls
• Demonstrate compatibility with Spectralux' quality system
• Meet external requirements such as Industry standards and regulatory and customer requirements
• Trace test and measurement equipment calibration/certifications to NIST standards or other appropriate and nationally recognized standards
• Provide evidence of a strong quality history
• Provide an acceptable first article
• When required by contract, comply with the process specifications (standards) documented in customer-defined criteria
• When required by contract, ensure both the supplier and all subcontractors use customer-approved special process sources
• When required by contract, be a customer-approved source for special processes
Spectralux is constantly searching for suppliers who can contribute to our success and our efforts to improve quality and the cost of our products.
Striving for efficiency, quality, and overall customer satisfaction
Spectralux relies on the principles of lean manufacturing to control costs and constantly improve quality. We’ve used tools such as SPC, 5S, and Kaizen successfully since 1997. Since then, we’ve reduced inventory investment and lead time. And we’ve consistently improved our efficiency, linearity of shipments, on-time delivery, and product quality. Our internal audits demonstrate a quality yield above 99.7 percent and an on-time delivery score above 99.9 percent. Our continuous improvement process meets AS9100 standards.
Our lean manufacturing processes result in unmatched product value and timely delivery, helping you reach your business goals. We have a high mix – low volume production line that can handle low volume as well as high volume orders. Our mix has evolved from (Machine, Paint and Etch) to complex assembly and test. Our low volume – high mix environment has our employees highly cross-trained to do multiple operations.
Spectralux puts into practice the concept of lean manufacturing. The concept of lean manufacturing is simply that the use of any resource not generating value for a customer is wasteful. Targeting and eliminating this waste helps increases efficiency and quality.
We at Spectralux have built lean into our manufacturing systems by utilizing various tools and ideas that enhance lean thinking and manufacturing throughout the operation. Some of the most recognized tools and ideas implemented by Spectralux are:
JIT (JUST IN TIME)
JIT is a strategy utilized by Spectralux to reduce in-process inventory and associated carrying costs. We implement this strategy using the Kanban system as well as various signals and visual cues to guide manufacturing and inventory replenishment.
5S OR "THE FIVE SS"
5S is the method used to organize our workplace. 5S as practiced by Spectralux is the idea of assigning everything a place so that time is not wasted looking for tools, equipment, materials, etc. We believe that the decision making process of deciding what should be kept, where it should be kept, and how it should be stored generates a clear understanding among employees of how and when work should be performed as well as a sense of personal ownership. When making these decisions, the primary focus is to promote the order and flow of items and actions to improve overall efficiency.
Each “S” in 5S stands for the following:
Sorting – Review all tools, materials, processes, etc., in the work area and keep only essential items that add value.
Setting in Order – Arrange tools, equipment, parts, etc., in a way that promotes work flow. For example, tools and equipment should be kept where they will be used.
Sweeping – Keeping the workplace clean and neat. At the end of each shift, the work area is cleaned up and everything is restored to its place.
Standardizing – Standardized work practices or operating in a consistent and standardized fashion. Everyone knows exactly what his or her responsibilities are.
Sustaining – Continuing to incorporate a 5S focus within each area after the initial 5S organization has taken place.
Poka-yoke is a Japanese term that means "mistake-proofing" — avoiding (yokeru) inadvertent errors (poka) or preventing errors by putting limits on how an operation can be performed in order to force the correct completion of the operation. Spectralux incorporates poka-yoke primarily within engineering to ensure that manufacturing can produce high quality products without mistakes.
Committed to excellence
Our entire team is in tune with the need for excellent Quality in the products Spectralux manufactures or repairs for you. We know that quality is the job of every employee, not something that is inspected in at the end of the process. Our philosophy is to plan for quality. We have created a production environment that relies on continually improving how we do our jobs. Quality is a mindset in all our employees. Each person, from the president on down, is committed to ensuring quality assurance activities that span the complete product cycle. From initial planning through development, design, production, and shipment we constantly strive to improve by making quality, on time delivery, and customer satisfaction our highest priorities. We stand ready to support you in any manner, and welcome you to visit our facility for a tour, for a system or product audit, or just to say hello.
“We will completely satisfy our aerospace customers by consistently meeting their evolving requirements for quality, regulatory compliance, value and on-time delivery. We are dedicated to continually improving our processes and providing highly reliable products and services.”
QUALITY MANAGEMENT SYSTEM – AS9100 REVISION D AND ISO 9001:2015
Spectralux Corporation is committed to meeting the highest quality standards using the latest tools and techniques. We are certified to AS 9100 Revision C and ISO 9001:2008 by BSI Management Systems. Our customer records demonstrate a quality yield above 99.7 percent and an on-time delivery score above 99.9 percent.
Spectralux maintains an internal audit program which meets the requirements of AS 9100. We are AS 9100 certified via BSI, an approved aerospace registrar. Our assessments are available on the Online Aerospace Supplier Information System (OASIS) database. Our repair station is FAA certified and we undergo routine FAA repair station audits.
Our customers are welcome to perform system audits of our company throughout the year. We welcome this activity as a way to understand your commitment to quality and view it as an opportunity to improve our systems. Please contact us to set an appointment.
INSPECTION AND TESTING
Inspection and testing may not be used to substitute for good quality practices. Inspection and testing is done to verify that materials and products meet the requirements and specifications of Spectralux Corporation and our customers. Inspection and testing is also used to verify that our good quality practices, and those of our suppliers, are in place and adequate. Checks are conducted when materials, components or products are received, at significant stages of production, and prior to release of finished products. Release of material or product at any stage, prior to completion of required inspections or testing, is strictly controlled, and the product is identified for later retrieval if necessary. Records are maintained of all formal inspection and testing activities.