W. Kolb Automates THT Assembly with FUJI sFAB-D
Manual Processes Replaced: Enabling High Volumes and Process Stability
Kelsterbach, May 7th, 2026 – While surface-mount technology (SMT) processes in electronics manufacturing are now largely automated, through-hole technology (THT) assembly often still relies on manual operations. W. Kolb Fertigungstechnik GmbH has now modernized this area in a targeted manner: by implementing the sFAB-D from FUJI EUROPE CORPORATION GmbH, the full-service electronics manufacturer has automated key THT assembly processes. This enables the company to produce high volumes with stable processes, repeatable accuracy, and consistently high quality.
W. Kolb has been manufacturing electronic assemblies since 1988 and, as a full-service provider, offers a comprehensive range of services—from production, testing, and inspection to logistics. The company employs around 210 people at its Willich site. In 2024, W. Kolb generated revenue of approximately €58 million and produced 10.5 million finished units, incorporating around 250 million electronic components.
Production is focused on demanding industrial sectors, including automotive, sensor technology, environmental technology, medical technology, and monitoring systems for rail vehicles. In SMT manufacturing, W. Kolb operates four high-performance ASMPT lines with inline SPI and AOI. The efficiency of all placement lines is monitored in real time via software and continuously optimized. In THT production, three lines with individual setups are available, including two wave soldering systems and one selective soldering system. THT assembly processes that could not previously be automated were traditionally performed manually.
“Our goal was to replace time-consuming manual insertion with a scalable automation solution—particularly for recurring tasks and high-volume production,” explains Timo Kluge, Head of SMT Production at W. Kolb. “After a comprehensive market analysis, we chose FUJI for the first time. The sFAB platform proved to be a technical benchmark in terms of precision, flexibility, and component variety.”
FUJI sFAB-D Handles the Majority of THT Assembly
With the integration of the sFAB-D, W. Kolb has significantly increased efficiency in THT assembly. The automated solution now handles the majority of insertion tasks, substantially reducing manual effort. At the same time, it ensures high processing speed and consistently high repeatability.
At W. Kolb, the system is equipped with two universal sH02 placement heads, including part presence check. Feeding is handled via a comprehensive feeder setup that supports radial and axial components as well as parts supplied in tube magazines. This allows processing of a wide range of THT components—from radial and axial parts to components in stick feeders.
“The sFAB-D has fully met our expectations. Thanks to the universal sH02 heads and the wide range of feeding options, we can now automate a large portion of our THT portfolio,” says Timo Kluge. “The combination of precision and speed enables us to ensure consistently high quality, even at high volumes.”
Smart Combination of Automation and Manual Assembly
At W. Kolb, the new solution does not replace existing THT expertise but complements it. While complex or specialized assembly tasks continue to be carried out manually, the sFAB-D handles standardized and recurring processes. This creates an efficient combination of automated assembly and flexible manual work.
At the same time, automation frees up employees to focus more on quality assurance and process-related tasks.
Fast Integration and Immediate Productivity
Installation and commissioning of the sFAB-D took place in March 2026. The system was integrated into existing production processes on schedule and was ready for productive use immediately after installation. Operator training was also completed quickly, enabling safe use of the system in day-to-day production within a short time.
The positive effects became evident early on: within the first month of full operation, the system proved itself in daily use and met high expectations in terms of reliability and performance.
Investment in Scalable Automation
This investment underscores W. Kolb’s strategic commitment to consistently advancing automation in electronics manufacturing. The goal is to reduce manual assembly wherever automated processes can deliver greater stability, speed, and quality.
W. Kolb also plans to further expand automation in the future and continuously optimize existing processes. The FUJI sFAB-D represents a key building block within THT production.
