Case Studies

Syrma Designs Custom Switched Mode Power Supplies

One of our recent clients is a European switched-mode power supply (SMPS) manufacturer that designs power supplies for niche applications. Their products are custom-made and meet the specific electrical, mechanical, and certification requirements of each customer. All involved international safety, electromagnetic compatibility (EMC), and electromagnetic interference (EMI) standards are considered. Originally, the client was getting their SMPS products manufactured in Taiwan; however, they decided to switch to using our manufacturing services due to rising costs. The client also viewed us as a complete ecosystem for SMPS manufacturing. We produce magnetic components, one of the key cost elements, and product quality.

Challenges

They wanted a manufacturing partner that offers ample resources, printed circuit board assembly (PCBA) capabilities with full box-build integration, and functional testing development combined with minimal barriers to entry for international production and sales. They also required that their partner meet the following specifications:

  • PCBA by customer quality standards, governing build criteria for solder joints, component placement tolerance, and other circuit board assembly verifiable aspects.
  • Full box-build capabilities to efficiently assemble internal components and external housings into finished units under one roof.
  • A localized supply chain provides bulk quantities of connection cables, power supplies, batteries, and other materials at shorter lead times and significant overall cost savings over long-distance imports.
  • Thorough QA review, with custom-developed system-level functional testing.
  • Enclosing finished units in the customer’s custom-designed packaging, bundled with all external accessories and product documentation.

Our world-class electronic manufacturing services (EMS) facility, combined with our experience as a magnetics component manufacturer, earned us their business. Our team quickly ramped up for the production of the customer’s products, coordinating the supply of materials with reliable nearby vendors. Once optimal production scaling was established, we warehoused finished inventory for direct shipment to resellers and end-user purchasers. As a solution, we created a build-to-print product. We brought to the table expertise in magnetics component manufacturing, resulting in lower cost, flexibility in terms of volume, and alternate sourcing.

We went through the rigorous process of new product introduction (NPI) on this SMPS product, integrating with the process of pricing, approval of magnetic parts, prototype approval for boards, and mass manufacturing, including the development of functional testers. As a result of our partnership, the client received a high-quality SMPS product that combined lower costs and flexibility. Importantly, it helped us gain the confidence of our customers and grow with them through several other programs.

Successes

We contribute our 40 years of design and manufacturing expertise spanning multiple diverse markets. We look forward to discussing how we can deliver world-class products for OEMs across the globe. We understand our home Indian market, familiar with its vast regulatory and selling environments. We foster growth opportunities within India through our strong technology incubation ecosystem. We also assist global OEMs in entering the Indian market by leveraging the local supply chain and favorable operating environments for cost reductions.

Our flagship Chennai location opened in 2006 and lies within a Special Economic Zone (SEZ) for electronics manufacturing, offering economic incentives for imports and exports. This primary facility is within 90 minutes of the Chennai seaport and 20 minutes to the international airport. Additional road and rail connectivity links to the rest of India and beyond and infrastructure advantages with faster import and export clearances. We also have labor force flexibility, both technical and manual, to scale to demand rapidly.

To learn more about this topic, please contact us.

Syrma SGS TechnologySyrma Designs Custom Switched Mode Power Supplies

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