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| Overview |
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Zenith Solar has developed a unique customer focused, low cost, high efficiency production system resulting in consistent, affordable, high quality solar energy solutions for facility heating, cooling and hot water. Zenith Solar production systems employ `best practices philosophy` with prime emphasis on employee recruitment selection and on-going training, a commitment to provide appropriate tools and technology, a commitment to high tech/high touch quality assurance systems and optimized outsourcing of non-critical operations, components and systems to maintain affordable cost structure and management focus.
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| Highest quality and reliability |
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Advanced Product Quality Planning (APQP) system is used to define customer expectations and requirements and ensure both Zenith Solar and our Tier 1- 3 Suppliers quality systems are aligned to deliver affordable, competitively superior performance at the highest level of reliability and ensure long life robust product durability. Advanced quality engineering methods including Quality Function Deployment (QFD), Statistical Process Control (SPC), Process Failure Mode Effect Analysis (PFMEA) along with 100% full load end of line testing, Computer Aided Engineering (CAE), Finite Element and Mold Flow Analysis, and full Design Verification Prove-Out (DVP) are employed to ensure full reliability of design, production, system operation and maintenance processes, validation of product and processes, certified quality assessments and follow-up corrective actions where necessary or advisable. Zenith Solar is committed to continuous process improvement.
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| Optic design |
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The Zenith Solar`s `Optics in Plastic` is the key to manufacturing efficiency and superior product quality achievement. A 2800 ton injection molding press uses advanced custom thermoplastic composition developed by our scientists for reliable, stable and long life operation. Our solar dish is injection molded with multiple gate radius heated runners to ensure even material flow and minimal warpage with rapid fill. Molding is completed in a world class facility with full material/environmental controls, material sampling and testing of each resin batch. Each dish is subjected to final product check on weighted custom jig fixtures and 3D product scan to ensure product accuracy. We purposely do not use long glass fibers to ensure wider recyclable product application.
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| Designed for recyclability |
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Uniquely specified composite structural materials, mirror panels, control and electronic systems are obtained from the ISO certified world class production suppliers to Zenith Solar exacting standards and unique quality requirements to ensure optimum performance and maximum service life. Key suppliers participate in Zenith Solar APQP System and are encouraged to provide error free products eliminating the cost of incoming quality control inspections as well as annual Value Analysis/Value Engineering (VA/VE) cost savings suggestion improvement program. Steel, composite and glass systems are specified with up to 100% recycled materials and are 100% recyclable. Electronics and control systems use 100% virgin materials and are not recyclable. Electronics and controls account for less than 5% of overall system by wight.
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| Production plant |
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Final fabrication, assembly and testing is completed in our production facility at Kiryat Gat, Israel, (across from the Intel Chip Fabrication) where our strict quality control measures ensure that each unit is subject to series of simulated lifetime testing verifications before sign off and release for customer installation. Each unit is individually released and tracked for lifetime performance with full feedback to production team for APQP ongoing quality and VA/VE cost improvements.
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| Field installation |
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Zenith Solar manages overall customer installation, set up, training and maintenance to track and ensure optimal life time system performance. Issues arising in the field are evaluated against product design Failure Mode Effect Analysis (FMEA) and used to modify on going Design Verification and Prove Out (DVP) for future model designs as well as maintenance and service operations processes to ensure optimum operating performance for all existing and planned field units.
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