Production quality and speed increased through use of SMD placement machines

Kelsterbach, 23. March 2023 – Time is the only resource that cannot be bought or produced. But it can be managed. Cycle times are a crucial factor in electronics manufacturing. To reduce cycle times and increase production quality and speed, Pyronix Ltd. uses the AIMEX IIIc SMD placement machine from FUJI EUROPE CORPORATION GmbH (www.fuji-euro.de), among others. Recently, the company invested in an additional AIMEX IIIc. In combination with the previously introduced FUJI solutions, Pyronix now has a highly flexible product line with different placement heads that solve different challenges in high-mix production.

Pyronix is a manufacturer and designer of electronic security equipment for use in home, business and industrial applications. The company develops a wide range of wired and wireless intrusion detection systems and relies on market-leading technologies exclusively designed by its in-house research and development team. Pyronix is constantly expanding and updating its production to be ready for the future.

High placement performance with a wide range of variants in production

As electronics production is becoming more complex due to ever smaller batch sizes, a greater number of varieties and an increasing number of components on a printed circuit board, the demands on placement are increasing. Pyronix therefore expanded its production with flexible placement machines. The company has been using various FUJI placement solutions, including those from the AIMEX family, for many years. Recently, an additional AIMEX IIIc SMD placement machine was purchased for the Rotherham South Yorkshire facility. This provides Pyronix with a complete, highly flexible product line at this site, including high-speed H24, versatile H08m heads and flexible DX heads. The expandable AIMEX IIIc supports Pyronix’s high-mix production with high placement performance and flexibility.

The Single-Robot DX head used in the AIMEX IIIC enables the placement of a wide range of parts with a single head, such as parts as small as 0.3 x 0.15 mm. This is possible because the head can automatically switch between different types of mini turrets during placement. The head applies a maximum pressure of up to 98 Newtons and can also optionally set adhesive dots. Various configurations of single- or double-track transport and with single or double robots are available.

“In terms of flexibility, precision and quality, we have taken our manufacturing to a new level with FUJI solutions and the recent deployment of the new AIMEX IIIC. After only a short period of use, we noticed that production quality and speed improved and that cycle times in product manufacturing were also reduced. The modularity offered by FUJI also allows us to react quickly to changing requirements. The placement solutions grow along with our needs,” explains Lee Reynolds, Supply Chain Director at Pyronix.

Electronic manufacturing and development company plans to further expand EMS business and strengthen market position

Kelsterbach, February 6th, 2023 – GEMAC Chemnitz GmbH (www.gemac-chemnitz.de) is specialized in sensor and measuring technology. The company manufactures its own products and provides selected customers with manufacturing services. In order to strengthen its market position, to technologically secure the targeted growth and to meet the increasing requirements of the growing miniaturization of electronic components, GEMAC is now relying on a complete line concept from FUJI EUROPE CORPORATION GmbH (www.fuji-euro.de). Among other things, six NXTIII placement machines were installed on the new production line. The total investment volume for these solutions is around 1.5 million euros. The goals are higher productivity and flexible high-mix production.

GEMAC Chemnitz GmbH has more than two decades of experience in the PCB equipment industry, specialized in small to medium-sized series. In the service sector, the company manufactures individual products from equipped PCBs to electronic components and complex devices according to customer requirements.

Tilo Rothkirch, Managing Director at GEMAC Chemnitz GmbH, explains: “We want to further expand our portfolio and continue to grow in the coming years. Since the demands on electronics manufacturing are constantly increasing, we can only generate the targeted development in this area with very powerful placement solutions. The pick-and-place machines we had been using up to now had neither the performance we wanted nor the flexibility we needed. They were more of a brake than an accelerator. We therefore decided to install a new production line at the beginning of the year.”

The overall line concept was developed by FUJI EUROPE CORPORATION GmbH. It includes six scalable NXTIII placement machines from FUJI as well as an oven from SMT Wertheim, handling modules from ASYS, a printer from EKRA and measuring & testing technology from GÖPEL electronic.

Flexibility and possibilities for development made the difference

FUJI EUROPE CORPORATION covers all areas of modern production in Europe: from highly flexible placement systems in high-mix to complete placement lines in high-volume.

The NXTIII placement machine is the core of the new production line at GEMAC. The modular and scalable solution is particularly suitable for the placement of multifunctional and high-performance electronics with, for example, high placement density of tiny components and much more. NXT III is designed for high productivity, placement quality, ease of use and speed.

Individualization, versatility and speed determine electronics production today. GEMAC expects the new placement machines and the other components of the line solution to make the company fit for the future.

Tilo Rothkirch says: “We expect increased throughput, with very high quality and flexibility at the same time. In addition, scalability and a high degree of automation mean that we can always adapt quickly to changing requirements. In particular, this also helps us to put into practice lessons learned from 2.5 years of global procurement crisis. This not only keeps us competitive, but ideally also gives us a competitive edge. The resource-saving properties of the new production line also support our efforts to achieve sustainability, which made it possible to obtain appropriate funding from the Free State of Saxony.”

With motivation and big goals into the new year! These are challenging times. But we are optimistic about the future and, despite all the circumstances in the market, are recording a very positive development of our company!

The year 2022 was marked by unexpected changes, challenges and emotions that occupy us in our private everyday lives and in the professional world. We have overcome some hurdles in the past year. Once again, we have proven as a team that we meet our challenges with passion, prudence and consistency.

This encourages us to start the year 2023 with motivation and ambitious goals. We want to build on our successes and have some further developments and innovations in store for you.

Machine for high-mix production equips smallest component size with the diameter of two human hairs

Kelsterbach, October 18th, 2022 – Placing around 30,000 components per hour – this is what Lawo is able to do with its new high-precision SMD production line from FUJI EUROPE CORPORATION (www.fuji-euro.de). The AIMEX IIIc machine platform used is designed for high-mix production – down to the smallest component size EIA 01005, enabling it to place components with a size of 0.4 x 0.2 mm at Lawo. This corresponds to the diameter of two human hairs.

Lawo entwickelt, fertigt und vertreibt Netzwerk-, Control-, Audio- und Video-Systeme für Fernseh- und Radio-Produktionen, Industrie- sowie Live- und Theateranwen­dungen. Lawo develops, manufactures and distributes advanced network, control, audio and video systems for television and radio productions, industrial as well as live and theater applications. “Our products and solutions are used especially for highly critical events. There is hardly a picture or sound signal in the transmission of global sports events such as World Championships or Formula 1 that does not run through a Lawo system. Absolute signal quality and fail-safety are a must here. Therefore, we have to meet the highest quality standards at all times,” explains Andreas Hilmer, Chief Marketing Officer at Lawo.

Added to this is the high speed of innovation in the industry, which is driven not least by product development at Lawo. Thus, production must be continuously adapted technologically. “Our production technology must therefore offer maximum precision on the one hand and be able to react flexibly to changes on the other,” adds Andreas Hilmer.

In order to secure Lawo’s future as a manufacturer of high-quality hardware products and to continue to offer full vertical integration, the company has invested around one million euros in its production facility in Rastatt. Among other things, a SMD production line from FUJI will be used. Three new automatic placement machines of the AIMEX series create higher efficiency and precision in on-site production. The new machines can now place around 30,000 components per hour – down to the smallest component size EIA 01005.

Optimized processes and higher degrees of freedom in production

The AIMEX IIIc machine platform is designed for high-mix production and enables any type of production and changes in the package shapes used. It supports in one machine the processing of smallest chip components up to large components. All placement heads used are equipped with the “Intelligent Parts Sensor” (IPS). This ensures seamless monitoring from component pickup to placement. The DX heads are highly flexible and change tools fully automatically, from dispensing tasks to mechanical gripping tools for odd-shaped components and chip-shooter tasks. The systems also open up high flexibility for operators. For example, the placement heads can be changed or adapted to an optimum machine configuration in just a few minutes without tools.

“With the new SMD line, we were able to significantly increase our existing placement capacity and quality. New degrees of freedom are also possible in terms of flexibility, precision and vertical range of manufacture. Thanks to the new production line, which also includes automated space-saving component storage cabinets and an integrated vapor phase soldering oven, we have been able to reduce the error rate to almost zero – and at significantly higher placement speed. In addition, the systems are highly flexible and expandable, which also gives us valuable room to maneuver for the future,” explains Andreas Hilmer.

The various 773 sItower is used as a production supply warehouse for the production line. It is able to accommodate 773 individual SMD reels from 7″ to 15″ and can be expanded to a capacity of up to 1,070 SMD reels via SmartCarrier boxes. In addition, the design of the 7″ and 13″ storage locations of the tower can be individually configured for diameter and belt width.

Throughput in placement more than six-fold – Growth consistently above industry average despite procurement crisis

Kelsterbach, July 25th, 2022 – With the installation of a new production line, EMS service provider Baudisch Electronicwww.baudisch-electronic.de) has raised its SMD production to a new level. The company was experiencing a steady increase in order volume and production was reaching its capacity limits with the previous isolated solution. Baudisch Electronic therefore decided to install an SMD line and realized this with FUJI EUROPE CORPORATION GmbH (www.fuji-euro.de) as general contractor. The throughput of the placement line is six times higher than with the previous solution. Quality and flexibility have been significantly increased by the new line solution.

As a full-service EMS provider with an EMC laboratory, Baudisch specializes in the production of prototypes as well as small and large series. The requirements in this environment are continuously increasing. Individualization, flexibility and speed determine production. For this reason, the new SMD line had to feature a high degree of automation and be capable of placing particularly small components such as 0201 (“008004”) as well as the greatest possible flexibility for odd-form parts up to 74 x 74 mm. Short setup times and lean production were further goals.

Performance improvement all along the line

Today’s SMD line features a transport system, laser, stencil printer, 3D SPI, SMD placement machine, reflow oven and storage system. The six modules of the NXT III placement platform from FUJI EUROPE CORPORATION GmbH form the core. FUJI is a manufacturer of highly flexible placement systems ranging from high-mix/low-volume to complete placement lines in the high-volume market. The company was the general contractor in the project and coordinated all parties involved.

“We have been able to decisively expand our range of services by using the new placement solutions. Our company now handles 01005 components, for example. We can also serve the high-volume sector today. As a result, we address a larger target group and have been able to acquire new customers,” explains Matthias Lenz, Managing Director of Baudisch Electronic GmbH.

At the same time, Baudisch Electronic has increased the placement performance many times in comparison to the previous system. Matthias Lenz sums up: “Already one week after the launch of the new SMD line, the first successes became visible. The output increased from 12,000 BT/h to currently 77,000 BT/h – at a better quality. The higher placement quality also significantly reduced the amount of rework required, and the automatic storage system led to shorter setup times.”

The even more consistent and better product quality results, among other things, from the implementation of the fully automatic SPI system for solder paste inspection, in-line marking by laser and the high-end assembly machines offered by FUJI. At the same time, a new traceability system has been adapted and there is complete traceability of all manufactured products.

Despite crises in the market: constant growth since acquisition of the SMD line

“Since 2020, we have been subject to major challenges due to the Corona pandemic as well as the raw material, energy and chip crises. Nevertheless, Baudisch Electronic’s growth has been consistently above the industry average since the acquisition of the SMD line. This is certainly due to our improved performance. Shorter delivery times, the highest product quality, and a flexible response to changes in orders at short notice – these are arguments that our customers appreciate all the more in these difficult times,” says Matthias Lenz.