Better design ensures a better quality product.




Fourstar engages with you to provide a product design that addresses the total cost of quality. We help you design your product to:

  • Meet or exceed industry workmanship standards
  • Address subtle requirements conducive to automated manufacturing processes
  • Ensure the most cost effective bill of materials content
  • Create a final design with the lowest possible cost of quality

As part of the design cycle, a test fixture is designed and a test program is written, to ensure that all products are 100% tested.

Compliance to ISO 9001:2015 and IPC-620B workmanship standards ensures consistent quality.

Employing best practices, including compliance to IPC-620B workmanship standards, and following an ISO 9001:2015 certified quality plan, Fourstar is able to provide a consistent level of workmanship and an overall quality that is repeatable over time. Our facility is ITAR compliant and our employees are trained in the IPC workmanship standards as well as J-Standard soldering skills.

The ISO 9001:2015 standard differs from the previous 2008 standard in a variety of ways.

The standard now follows the high-level structure used in all standardized management systems, which will make the integration of various management systems simpler. ISO 9001:2015 put more emphasis on input and output of processes. This means that articles, information, and specifications that are involved in the production process must be closely monitored and clearly checked for quality.

One of the unique parts of the new ISO 9001:2015 is that it compels us to assess risks and identify opportunities. The language of the standard explicitly expects risk assessment and avoidance, which means we use risk analysis to navigate business decisions for Fourstar and our customers. By continually examining opportunities for improvement, it enables Fourstar to implement operational controls to effectively manage and measure our performance.

Other new factors that are prominent in ISO 9001:2015 are:

  • Context of the organization—apply holistic considerations for all parties involved, requiring how an organization defines internal and external influences
  • Interested parties not limited to customers—include suppliers, personnel, shareholders, legislative bodies, society, internal customers, etc.
  • Leadership and commitment—integrate business processes and strategies to control the quality management process
  • Documentation—information can be accepted in a wide variety of formats, streamlining documentation with focus on vital processes that address risk

RoHS Compliance

Cirrus Easy Wire CR testerFourstar has developed a comprehensive plan for meeting RoHS compliance. The plan includes determining the RoHS compliance status of all material—starting with purchasing through receiving inspection—and ultimately when the material is issued and used to build a final assembly. As part of this process Fourstar is able to test for RoHS compliance using a Thermo Scientific”: Niton model XLt797Y.

This portable XRAY gun is able to break down the composition of the part and compare that to the RoHS requirements and validate compliance or non-compliance. This is the only true way to confirm compliance to the standard. The gun can also be used at final inspection to validate that the completed assembly has not been contaminated in the manufacturing process.

Fourstar provides 100% continuity testing using Cirrus Easy Wire CR testers.

Cirrus Signature Easy Touch TesterFourstar uses Cirrus Easy Wire CR testers to check for continuity as part of its process control and final inspection process. These testers are PC-based versus the less reliable “self-learn testers” used by many of our competitors. The advantage of these testers is that the programs are saved to a hard drive and can be used simultaneously at multiple workstations. In addition, the programming for these testers is done by qualified engineering or quality personnel, who understand the customer schematic and ensure that all test points are programmed and accounted for. Once the program is generated, the actual test programs are password protected and cannot be modified by the operators.

Since the test programs are looking at all potential points for continuity, a failure will be detected in either the cable under test, or in the test fixturing itself. This ensures that no test points are missed and guarantees repeatability from lot to lot. Self-learn testers are more susceptible to missing test points or changes in the program that result in inconsistent testing over time.

In addition to guaranteed repeatability, test data that is collected during manufacturing can easily be shared electronically. This capability allows Fourstar to provide serialization and formal test reports with each shipment as required by the customer.

Fourstar provides Hi-Pot testing with Cirris Signature Easy Touch Tester.

back-wired forming boardsIn addition to continuity testing, Fourstar can also provide Hi-Pot testing using the Cirris Signature Easy Touch tester.  This tester will verify continuity and then perform sequential Hi-Pot testing that is programmable up to 2000V with defined dwell times.

Fourstar provides 100% testing of complex wire harnesses using custom back-wired forming boards.

As part of the product design phase, Fourstar develops a custom back-wired forming board for use in the manufacture of complex wire harnesses.  These custom boards are populated with the appropriate mating connectors that are then back-wired to the Cirris Easy Wire CR tester.  The boards are built dimensionally correct to the customer drawing, so that the test will not only verify electrical compliance but will also act as a Go-No-Go fixture that verifies that the harness is dimensionally correct.  Using manufacturing specified mating connectors, the testing of the harness exactly duplicates the electrical and mechanical environment of the harness and ensures that it will work the first time, every time.