Custom Manufacturing

ISL specializes in build-to-print complex electronic assemblies and cable/harness assemblies, and the design and fabrication of composite material structures. Our team consists of highly experienced assembly and manufacturing, material handling, procurement, quality and test specialists who are “Committed to Excellence.” 15,000 Square-foot Manufacturing Floor, Personnel Certified to IPC-A-610 and J-STD-001, ISO 9001:2008 Certified.

 

Composite Material Fabrication

ISL employs a team of highly skilled composite structure technicians, the ISL team is highly experienced in design and fabrication of UAV composite material structures. ISL’s Huntsville facility can produce small to medium size composite molds and structures in a secure environment. Our curing oven is large enough to handle medium size structures. We also have a ShopBot™ CNC controlled large milling and forming machine that can handle medium sized molds.

Electronic Assemblies And Cable/Harness Assemblies

ISL’s full “Turn-Key” capability includes assembly and test of cables, electronic sub/final assemblies and system integration. Utilizing classified personnel with classified assembly and test areas, production capabilities adapt easily to engineering drawings/concepts for prototype builds. We have flexible, cellular manufacturing set up with materials on METRO carts and cells can be easily modified (within hours) to accommodate surge demands. All elements are in place to support a manufacturing facility with extensive test equipment and test capabilities, environmental stress screening and, efficient organization offering quick turn quality products and on time deliveries with sufficient floor space to grow.

Production Personnel Certifications

All manufacturing assemblers and technicians are certified to:

  • IPC-A-610 Acceptability of electronic assemblies
  • WHMA-A-620 Requirements /acceptance for cable & wire harness assemblies
  • IPC-7711 Rework of electronic assemblies
  • IPC-7721 Repair & modification of printed circuit boards & electronic assemblies
Production Experience

ISL prides itself on employing seasoned manufacturing personnel with an average tenure of 25 years. With a “can do” attitude and a proven track record, this very aggressive production force has produced products for both commercial and military customers, mostly mission critical electronic hardware. These include:

  • Submarine sonar equipment
  • Spectrum analyzers
  • Machinery vibration diagnostic systems
  • Aviation vibration diagnostic systems
  • Circuit breaker electronics for submarines
  • Radio and antenna systems for DOD
  • Class 1 NSA crypto equipment
  • Harness and cable assemblies for helicopters & unmanned airships
Quality Assurance

Quality Management System is approved to ISO9001:2008 and acceptability criteria are based upon established Workmanship Standards. ESD control and manufacturing processes are detailed in department operation procedures and Detailed Routers accompany the product through the manufacturing process. Inspection areas include receiving, in process and final inspection. ISL uses an internal auditing system with rotating internal auditors, and a supplier survey and approval system.

Materials Management

ISL uses the Deltek Materials Management Business System with internal departments for Production Control, Purchasing, Material Control and Stockroom/Shipping/Receiving. Material requirements are generated through the MRP process and the Just In Time method of material receipts is used. ISL has an established supplier base with documented acceptance and on time delivery criteria. Material, at all times, is fully ESD protected.

New Business Production Approach

ISL utilizes an Assigned Manufacturing Program Manager – single point of contact, and assigned Cell Leads for both assembly and test areas. Also important to ISL’s business production approach are dedicated production cells using assigned personnel, a fully developed production plan based on the MRP process, develop and map (Kaizen) cell and material layout for optimum efficiency, and fully documented and controlled assembly aids and instruction. Developing strong partnerships with key suppliers, striving for continuous improvement, providing training as required, being proactive with status and responding quickly to the customer are some of the valuable assets ISL employs in its approach to business production.