Semi-Custom Workflow

UNIFIVE's semi-custom power supply development workflow is explained in 8 steps. By using standard products as a base, we can offer short lead times, low costs, and certification based only on the differences. For those considering AC/DC Power Adapter or switching power supplies, we introduce the entire process, from inquiry and model selection to specification finalization, prototyping, certification, mass production, and continuous supply.

1. Semi-Custom Workflow Features

Semi-customization involves modifying certain specifications of our standard products to meet customer requirements. Compared with full customization, which requires a new design, it can meet requirements while significantly reducing development time and costs.

The semi-custom workflow has the following features that are not found in full customization.

• No new design process required: Since the optimal base model is selected from a lineup of more than 1,500 standard products, no new circuit, transformer, or enclosure design is required.
• Existing certifications can be utilized: Safety certifications such as PSE, UL, and CE already obtained for the base model can be utilized, and in many cases, only differential certification for the modifications is required.
• Short lead times: Depending on the specifications, mass production can be launched within several weeks to several months.
• Lower initial costs: Since there are no costs for new mold fabrication or circuit design, development investment can be minimized.
• Suitable for small to medium production runs: Since no mold investment is required, projects involving annual volumes ranging from several hundred to several thousand units can also be accommodated.

Difference from full customization: Full customization involves entirely new development, from market research and design to prototyping and mass production. In semi-customization, the base model replaces this new development process, and only the modifications are designed and evaluated. For details on the full-custom development process, please refer to the Full-Custom Workflow page.

2. Overall Workflow

The semi-custom process consists of the following eight steps. We provide comprehensive support from the initial inquiry and mass production launch through ongoing supply.

3. Details of Each Step

This section explains what takes place at each step and what information is exchanged.

STEP 1: Inquiry and Requirements Consultation

We will discuss your requirements through our inquiry form or with our sales team. Specifically, we will confirm information such as the following:

• Equipment application and intended use
• Required output specifications (voltage, current, USB PD profile, etc.)
• Mechanical requirements (enclosure size, cable length, connector type)
• Operating environment (ambient temperature, humidity, indoor/outdoor use, vibration, installation configuration)
• Destination markets and customers (relevant to the required safety standards)
• Required number of prototype samples and desired delivery date
• Planned start date for mass production and estimated annual quantity
• Delivery destination (domestic factory, overseas factory, etc.)
• Operating conditions (load factor, operating hours, required service life, etc.)

Providing existing specifications, circuit diagrams for the equipment, or the model number of the adapter being replaced will help the subsequent evaluation proceed smoothly.

You may consult us even if some details have not yet been determined. Please let us know which items remain undecided, and we will proceed with the evaluation accordingly.

STEP 2: Base Model Recommendation

Based on the information gathered during the consultation, we will select and recommend the base model that most closely meets your requirements from our lineup of over 1,500 standard products. If there are multiple candidates, we will explain the features and degree of suitability of each one.

If you are considering replacing another company's Products, we will use our cross-reference search to recommend one of our standard products with similar specifications.

STEP 3: Discussion of Modifications and Finalization of Specifications

Using the base model as a starting point, we will discuss the modifications required to meet your requirements. Typical modifications include the following:

• Output cable length and connector type
• Input plug replacement (by destination)
• Output voltage and current adjustment
• Optimization of overcurrent protection (OCP) characteristics
• Extended service life through changes to electrolytic capacitor specifications
• Nameplates, engraving, and logo printing
• Moisture-resistant coating and changes to waterproof and dustproof ratings
• Changes to packaging specifications and included accessories

At this stage, you will review the draft technical specifications, and the specifications will be finalized upon mutual agreement.

STEP 4: Quotation and Schedule

Based on the finalized specifications, we will provide a quotation that includes the following:

• Initial costs (if applicable)
• Unit price for mass production
• Minimum order quantity (MOQ)
• Prototype schedule
• Schedule through the start of mass production
• Time required to obtain certifications (varies by destination)

For semi-custom products, some projects may be handled with no initial costs.

We will provide separate schedules indicating when prototype samples can be delivered and when procurement of mass-production components can begin. The country of manufacture and shipping terms will also be provided with the quotation. Quotations can also be issued in foreign currencies upon request.

For information about lead times after placing an order, small-lot orders, and international delivery, please also see the following pages.

• How long does it take from placing an order to receiving it?
• What is the minimum quantity for small-lot orders?
• Purchasing and Delivery Routes

STEP 5: Prototyping and Customer Evaluation

We manufacture a prototype and provide it to the customer. The customer evaluates it in combination with the actual equipment, verifies its operation, and assesses its reliability.

For electrical performance, we provide verification measurement data obtained after tuning. For items related to national laws and regulations, such as EMC and noise, we provide data obtained from an accredited laboratory.

If minor specification adjustments are required based on the evaluation results, we address them by producing another prototype or making partial modifications.

STEP 6: Certification for Modifications

A major advantage of semi-custom products is the ability to leverage the safety certifications already obtained for the base model. Depending on the modifications, products may be shipped without recertification, or only the modifications may require additional certification.

We support obtaining the necessary certifications for modifications according to the destination, including PSE in Japan, UL in North America, CE/GS in Europe, CCC in China, KC in South Korea, and BSMI in Taiwan.

STEP 7: Mass Production and Quality Inspection

Production begins at the mass-production facility. We conduct the following three stages of quality inspection for mass-produced products.

• Incoming Quality Control (IQC): We conduct sampling-based incoming inspections and hazardous substance inspections on all components, excluding certain packaging materials.
• In-Process Quality Control (IPQC): We verify that production complies with specifications, ultrasonic welding is performed properly, and processes proceed according to work instructions for every production lot.
  We also conduct insulation resistance tests, dielectric withstand voltage tests, and other tests on semi-Products and finished products for every production lot to verify quality.
• Outgoing Quality Control (OQC): We use sampling inspections to verify electrical characteristics based on safety standard requirements and specifications for every production lot.

Our inspection criteria follow Level II of ANSI/ASQ Standard Z1.4, with AQL standards established for critical, major, and minor defects. For details, please refer to the Quality Initiatives page.

STEP 8: Continuous Supply and After-Sales Service

After mass production begins, we provide long-term continuous supply and after-sales support.

• Traceability Management: We retain production history data for 20 years, enabling long-term quality tracking.
• Defect Response: In the event of a defect, we conduct an analysis, identify the root cause and the cause of its escape, and implement measures to prevent recurrence.
• Support for Derivative Products and Additional Specifications: After mass production begins, we flexibly accommodate derivative products with different cables and additional specifications for new destinations.
• Long-Term Supply: We monitor component procurement conditions to support a stable long-term supply.

4. Contact Us

Our sales team provides consistent support for semi-custom solutions, from discussing your requirements to recommending a base model. Please feel free to contact us even if you are unsure whether you need a fully custom solution. We will first determine whether your needs can be met by our standard product lineup.

Inquire About Semi-Custom Solutions

Request a General Products Catalog