Workflow for semi-custom orders

UNIFIVE explains its semi-custom power supply development workflow in 8 steps. Based on standard products, it enables short lead times, low cost, and compliance through differential certification. From inquiry and model selection to specification finalization, prototyping, certification, mass production, and ongoing supply, this guide introduces the process for those considering AC/DC Power Adapter and switching power supplies.

1. Features of the Semi-Custom Workflow

Semi-custom solutions are customized based on our standard products, with certain specifications modified to meet customer requirements. Compared to full custom development that involves new design, this approach significantly reduces development time and cost while achieving compliance with required specifications.

The semi-custom workflow has the following characteristics that differ from full custom development.

• No new design process required: Since the optimal base model is selected from a lineup of over 1,500 standard products, no new design of circuits, transformers, or enclosures is required.
• Existing certifications can be utilized: Safety certifications such as PSE, UL, and CE already obtained for the base model can be leveraged, and in many cases only partial certification for the modified portions is required.
• Short lead times: Depending on the specifications, mass production can begin within several weeks to several months.
• Lower initial costs: As there is no need for new mold fabrication or circuit design, development investment can be kept to a minimum.
• Suitable for small to medium lots: Without mold investment, projects with annual volumes of several hundred to several thousand units can be accommodated.

Difference from full custom: In full custom development, everything from market research to design, prototyping, and mass production is newly developed from scratch. In semi-custom development, the new development process is replaced by a base model, and only the modified portions are designed and evaluated. For the full custom development flow, please refer to the Full Custom Workflow page.

2. Overall Workflow

Our semi-custom process proceeds through the following 8 steps. We provide comprehensive support from initial inquiry to mass production launch and ongoing supply.

3. Details of Each Process

We will introduce what is carried out in each process and what kind of information is exchanged.

STEP 1: Inquiry and Requirements Hearing

We will conduct a hearing of your requirements through the inquiry form or via our sales representative. Specifically, we will confirm the following information.

• Equipment application and intended usage
• Required output specifications (voltage, current, USB PD profile, etc.)
• Mechanical requirements (enclosure size, cable length, connector shape)
• Operating environment (ambient temperature, humidity, indoor/outdoor, vibration, installation conditions)
• Destination country and sales market (related to required safety standards)
• Expected lot size and desired delivery date
• Usage conditions (load factor, energization time, required lifespan, etc.)

If you can provide existing specification documents, circuit diagrams of the equipment, or the part number of the adapter to be replaced, subsequent evaluations can proceed more smoothly.

STEP 2: Proposal of Base Model

Based on the information obtained during the consultation, we will select and propose the base model that best matches your requirements from our lineup of over 1,500 standard products. If multiple candidates are available, we will explain the features and suitability of each option.

If you are considering replacing a competitor's Products, please use our cross-reference search to find and propose a comparable standard product from our lineup.

STEP 3: Discussion of Modifications and Specification Finalization

Starting from the base model, we will discuss the items that require modification to meet your requirements. Typical modification items are as follows.

• Output cable length and connector type
• Input plug replacement (by destination country)
• Adjustment of output voltage and current
• Optimization of overcurrent protection (OCP) characteristics
• Extended lifespan support through specification changes of electrolytic capacitors
• Nameplate, engraving, and logo printing
• Moisture-proof coating and changes to waterproof and dustproof grade
• Changes to packaging specifications and included accessories

At this stage, we will ask you to review the draft technical specification document, and the specifications will be finalized upon agreement.

STEP 4: Quotation and Schedule Proposal

Based on the finalized specifications, we will provide a quotation including the following details.

• Initial cost (only if required)
• Mass production unit price
• Minimum order lot (MOQ)
• Prototype schedule
• Schedule until mass production launch
• Time required for certification acquisition (varies by destination country)

In the case of semi-custom projects, there are cases where we can proceed with zero initial cost depending on the project.

STEP 5: Prototype and Customer Evaluation

We will manufacture a prototype unit and provide it to you. On your side, you will conduct combined evaluation with the actual equipment, operation verification, reliability testing, etc.

Regarding electrical performance, we will provide verified measurement data after tuning by our company. For items related to national regulations such as EMC and noise, we will provide data obtained from certified laboratories.

If fine adjustments to the specifications are required based on the evaluation results, we will respond with a re-prototype or partial modifications.

STEP 6: Certification Gap Handling

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, shipment may be possible without re-certification, or only gap certification for the changes may be required.

We support the acquisition of gap certifications according to the destination country, including Japan's PSE, North America's UL, Europe's CE/GS, China's CCC, Korea's KC, and Taiwan's BSMI.

STEP 7: Mass Production and Quality Inspection

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

• Incoming Inspection (IQC): Sampling-based incoming inspections and hazardous substance testing are conducted on all components except for some packaging materials.
• In-Process Inspection (IPQC): For all lots, we verify production in accordance with specifications, proper ultrasonic welding, and progress in line with work instructions.
  In addition, insulation resistance tests, dielectric strength tests, and other evaluations are conducted on all production lots for Semi-Products and finished products to confirm quality.
• Outgoing Inspection (OQC): Electrical characteristics based on safety standard requirements and specifications are inspected by sampling for all production lots.

Inspection standards adopt ANSI/ASQ standard Z1.4 Level-II, and AQL criteria are established for critical, major, and minor defects. For details, please refer to the Our Quality Initiatives page.

STEP 8: Continuous Supply and After-Sales Service

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

• Traceability Management: We store production history data for 20 years, enabling long-term quality tracking.
• Defect Handling: If a defect occurs, we conduct an analysis, identify the root cause and outflow cause, and implement measures to prevent recurrence.
• Support for Variants and Additional Specifications: After mass production begins, we flexibly support derivative products with different cables and the addition of specifications for new destination markets.
• Long-Term Supply: We monitor component procurement status to support stable long-term supply.

4. Contact Us

For semi-custom inquiries, our sales team provides comprehensive support from hearing your requirements to proposing a base model. Even if you are unsure whether a full custom solution is necessary, please feel free to contact us. We will first consider whether our standard product lineup can meet your needs.

Contact Us About Semi-Custom Solutions

Request the General Products Catalog