Increasing demand for security sensors necessitates expansion of placement capacities

Kelsterbach, May 14th, 2024 – ELESTA GmbH, a company within the PILZ Group, has expanded its placement capacity with machines from FUJI. Drivers are increasing demand and growing complexity in the sensor field. ELESTA develops and produces sensors for industrial automation, particularly in the area of functional safety. To ensure the high standards of its products, the company is expanding its production facility with a new placement line from the NXTR series consisting of five NXTR S placement modules from FUJI EUROPE CORPORATION GmbH ( www.fuji-euro.de).

ELESTA places various flat assemblies from rigid and semiflexible printed circuit boards, which are used in safety sensors. These sensors serve, among other things, for monitoring safety doors and access control of machinery and equipment. The portfolio ranges from magnetic and mechanical interlocks to Reed and RFID sensors to safety light curtains. Furthermore, ELESTA is globally active as an innovation leader in relays with forcibly guided contact sets according to IEC 61810-3.

“With the constantly growing demand for our sensors and the increased complexity of the products, accompanied by an increase in electronic components on the controllers, it became necessary to expand the placement capacity,” explains Dario Berni, Head of Production Sensors and SMD at ELESTA GmbH.

Therefore, the decision was made by the responsible parties to replace the existing FUJI placement line NXT II. It was replaced by a system consisting of five placement modules from the NXTR S series. The new placement machine offers better printed circuit board handling, more CPH (components per hour), higher flexibility regarding component size with fewer head types. Exchange heads, units, and even complete modules can be replaced without tools. In addition, predictive maintenance is possible with self-diagnosis. This minimizes unplanned production interruptions.

“With the introduction of the new placement system FUJI NXTR S, flat assemblies with very fine structures and high component density can be manufactured with high efficiency. Furthermore, production flexibility is increased, and throughput times are reduced. ELESTA is thus ideally equipped for the needs of the coming years,” says Dario Berni.

The automated and autonomous production is gaining momentum

Kelsterbach, April 3rd, 2024 – Companies have never had to adapt to changing market demands and scale production as rapidly as they do now. Automation is the lever to easily align processes with different product types or production quantities. This also applies to placement. FUJI EUROPE CORPORATION GmbH ( www.fuji-euro.de) will showcase components for the FUJI Smart Factory 2.0 at SMTconnect from June 11th to 13th in Nuremberg (Hall 4, Booth 4-321), including various placement machines and newly developed RH placement heads. The goals: zero placement errors, zero machine operators, zero machine stops.

At the exhibition, FUJI presents components of a Smart Factory for SMT and THT placement, which are interconnected in a production line according to the principles of Industry 4.0 via M2M communication with machines from other companies. In the FUJI Smart Factory 2.0, all production-relevant tasks, starting from material preparation and extending beyond printing and placement processes, are intelligently interconnected. The result is a 22 percent reduction in production times.

The R machine series optimizes production preparation and maintenance processes, while automating manual placement processes for comprehensive networking and self-optimized production. In SMT placement, the NXTR-S offers a modular design that allows for quick adjustments to changing production needs. Heads, units, and even entire modules can be replaced without the need for tools. Additionally, the AIMEXR is designed for uninterrupted operation and can accommodate up to 130 different part types, producing panels with dimensions of up to 1,068 x 610 mm.

The sFAB-D, a placement machine designed for automated placement production, streamlines the labor-intensive THT (Through-Hole Technology) placement process, significantly enhancing efficiency while ensuring high precision. This machine offers flexibility to accommodate various part sizes, shapes, and delivery methods, ranging from wired components to larger specialized parts like transformers.

Automation fosters flexibilization

In FUJI’s Smart Factory, automation is aimed at liberating manual tasks and simplifying processes, ultimately speeding them up. This objective also contributes to enhancing the flexibility of SMT manufacturing.

“The complexity, customization, and miniaturization in SMT manufacturing are on the rise.For placement, this means it must be flexible enough to adapt to various components and groups, without compromising precision,” explains Stefan Janssen, Managing Director of FUJI EUROPE CORPORATION GmbH

These challenges are supported by the new RH placement heads that FUJI is presenting at the trade show. Among other features, they offer the ability to adjust the clearance height of the placement heads using a so-called sub-Z-axis. With the help of the contact sensor on the head, it is checked whether the part has touched the circuit board. ‘This precision and adaptability increase flexibility in manufacturing and can be particularly useful when processing various components or assemblies that have different requirements for placement,’ says Stefan Janssen.”

The new RH placement heads that FUJI is unveiling at the trade show are compatible with the R machine series (NXTR-A/-S as well as AIMEXR). By combining a newly developed 2RV module with RH28 heads, W08t feeders, and MFU-63 feeder carts, the NXTR achieves a throughput of 120,000 cph (on a 795 mm module length). This represents a 39 percent improvement compared to the NXT III placement machine.

Stefan Janssen explains: “At SMTconnect, FUJI demonstrates further automation solutions that minimize manual tasks, thereby addressing the growing shortage of skilled labor. At the same time, alongside flexibility, high-speed, and high-precision placement, we are increasingly focusing our machines on energy efficiency in line with the urgent need for an industrial energy transition.”

Visitors can experience the NXTR-S in action firsthand via ‘Robust Processes and Technologies through Automation and Digitalization’ as part of the Future Packaging Line, located at booth 4-311 in Hall 4, hosted by Fraunhofer IZM.”

More automation – even in traditionally manual processes such as THT

Kelsterbach, January 10th, 2024 Automation is increasingly finding its way into the PCB manufacturing process – even in areas that are considered to be the last remaining labor-intensive manual processes, such as THT production. With its sFAB-D, FUJI EUROPE CORPORATION (www.fuji-euro.de) offers a machine for the automation of THT placement processes, which are often still carried out manually. The AIMEX IIIc also enables automated processes for flexible high-mix production and higher productivity. FUJI will be showcasing both solutions at “Southern Manufacturing & Electronics” from February 6-8, 2024 in Farnborough (UK) at stand L80.

Placement processes today are subject to constantly growing requirements with regards to high-mix or variable-mix and variable-volume production. This calls for solutions which enable processes to be adapted quickly and easily and increase speed.

“Speed and flexibility are among the main reasons why many of our customers are increasingly turning to automation – even in areas that have been managed manually for decades,” explains Martin Rennie, Branch Manager UK at FUJI EUROPE CORPORATION GmbH.

The AIMEX IIIc all-in-one placement machine supports all types of production and changes in used package shapes. It allows easy ramp-up of new productions or reaction to changes in package shapes and any errors that occur. Several test functions prevent defects and ensure high quality. Reduced time and labor costs are drastically minimized by advantages such as the reduction in the number of changeovers. Operation is extremely simple thanks to the use of pictograms.

Continuity and flexibility required

Alongside AIMEX IIIc, FUJI is also presenting sFAB-D, a placement machine for automated PCB production, at the “Southern Manufacturing & Electronics” in Farnborough (England). The platform automates THT (Through-Hole Technology) placement processes and thus increases efficiency significantly – while maintaining high precision. It flexibly supports various part sizes, shapes and delivery types, from leaded components to large special components such as transformers, etc.

Through-hole technology is a labor-intensive method for manufacturing PCBs, as components are inserted through holes on the board and then soldered on the other side.

Vasilii Afanasev, sFAB Manager at FUJI EUROPE CORPORATION GmbH, explains: “Inserting and soldering the components is usually done manually and is therefore very time-consuming. The automation of THT board placement provides an alternative. It relieves employees of laborious, monotonous work and makes the placement workstations more effective. It also helps to ensure quality. Modern production relies on automated processes to ensure the high level of efficiency and competitiveness that is essential today.”

FUJI will be exhibiting both placement machines at “Southern Manufacturing & Electronics” from February 6 – 8, 2024 in Farnborough (UK) on stand L80.

Specialist for placement machines forces productivity increase and a more sustainable future with “R” machine series

Kelsterbach, 21 September 2023 – The electronics industry is in the midst of digital transformation. The sector and production requirements are changing. With its “R YOU READY?” campaign, FUJI EUROPE CORPORATION GmbH ( www.fuji-euro.de) is helping companies to solve the challenges posed by this change. In the course of this, the specialist for electronics placement machines is presenting its “R-Series” at “productronica 2023”. These are machines that reduce manual activities to a minimum and are aimed at energy efficiency, flexibility, high-speed and high-precision placement. At the show, FUJI will showcase these and other solutions for automated and flexible placement in Hall A3, Booth 317.

The electronics industry is facing growing challenges. On the one hand, digitization and networking must be driven forward – equipment and systems must be able to communicate seamlessly with each other for end-to-end processes and be integrated into software landscapes. At the same time, market players are facing staff shortages, a lack of raw materials, the energy crisis and fluctuations in demand with rising production costs. Competitive pressure is high.

“Productivity in manufacturing has never been as important as it is today. With our “R” placement machines, we aim for highly efficient and agile production that is also designed for sustainability. Our placement machines of the R-Series support a wide range of production types and prove to be very economical and energy-saving,” says Stefan Janssen, Managing Director of FUJI EUROPE CORPORATION GmbH.

At “productronica”, FUJI will demonstrate various automation solutions as well as an electronics production line without human intervention, consisting of the NXTR PM printer and the NXTR A placement machine, with a connection to an AMR (Autonomous Mobile Robot). This allows FUJI to show visitors the interaction of the machines, the heart of the FUJI Smart Factory 2.0, and in the course of this the newly developed RH placement heads, which are used in the R series. The NXTR A automates previously manual processes such as feeder exchange and material replenishment. This frees machine operators from feeder exchange and parts supply tasks, which usually account for the largest share of the operator’s work in front of the placement machines.

Automation and sustainability in placement

The NXTR A and NXTR S placement machines belong to the “R” machine series. They offer a modular design that allows quick adaptations to changing production requirements. Heads, units and even entire modules can be changed without tools. Predictive maintenance is enabled by self-diagnostics that prevent sudden machine stops from affecting the production schedule.

The NXTR models support high-speed panel production, with a high throughput without compromising on quality. The intelligent sensor system ensures stable and high-quality placement. The status of the machine is monitored in real time and the load on components and panels is controlled at the same time.

“In response to market demand, we have released new 2RV modules as part of our NXTR S. The 2RV modules are even faster than the NXTR modules without compromising the transportability of the NXTR modules. The NXTR modules have the largest supported plate size among the NXT machine series. This makes the 2RV modules suitable for a wide range of production, including automotive panels, mobile devices, LED displays and much more,” explains Stefan Janssen.

The third and last in the alliance of the R-series is the new placement solution AIMEXR, which also addresses several central challenges of SMT production: Energy saving, individualization and flexibility as well as speed and efficiency. The solution is designed for uninterrupted operation while reducing energy consumption by around ten percent compared to previous solutions. The AIMEXR can accommodate up to 130 different part types and produce panels up to 1,068 x 610 mm, a very high level of versatility.

In addition, FUJI’s support tool “mobile Conductor” makes it possible to schedule woman and manpower in order to save walking distances. This results in reducing downtime, as operators are informed and can act immediately. Notifications can also be made for non-FUJI equipment.

Automation solutions for the entire process chain

At “productronica”, FUJI will also be showing other solutions and tools that enable fully automated processes. “Our aim is to continuously increase efficiency throughout the entire process chain of placement, while at the same time reducing the environmental impact. With our placement machines, we support, among other things, the optimization and automation of logistics, maintenance and changeover processes. This saves time, effort and ultimately energy,” says Stefan Janssen.

E²MS-Dienstleister zielt auf höhere Geschwindigkeit und Flexibilität

Kelsterbach, 2. August 2023 – In der Elektronikfertigung sind die Auftragsbücher derzeit vielerorts prall gefüllt. Der E²MS-Spezialist ETB electronic erhöht daher seine Fertigungskapa­zitäten und legt dabei Wert auf Flexibilität. Das bedeutet, das Unternehmen möchte in Zukunft die Fertigung an aktuelle Anforderungen besser anpassen können. Im ersten Investitionsschritt kommen in der 4.000 qm großen Produktionshalle sechs skalierbare Be­stückungsplatt­formen NXTIII zum Einsatz, ein Konzept der FUJI EUROPE CORPO­RATION GmbH (www.fuji-euro.de). Auf ins­gesamt fünf Produktions­linien sollen sukzessive weitere Bestückungsauto­maten von FUJI installiert werden, um eine hocheffiziente und agile Fertigung zu erreichen.

Die 1983 gegründete ETB electronic entwickelt, produziert und montiert technisch anspruchsvolle Elektronik und komplette Geräte. Das Unterneh­men beschäftigt rund 200 Mitarbeitende und hat die Hauptkundschaft in den Be­reichen Industrie, Maschinenbau, Automatisierung, Medizintechnik und Automotive.

Der E²MS-Spezialist strebt eine hochautomatisierte Fertigung an. In der im Jahr 2022 erweiterten Produktionshalle werden Muster, Vorserien und Serien gefertigt. In der SMD-Bestückung kommen bislang auf vier Linien Bestücker eines anderen Anbieters zum Einsatz.

Mit flexibler Technologie schnell an Veränderungen anpassen

Für die Zukunft möchte ETB electronic noch schneller auf neue Kundenbedürfnisse und Nachfrageschwankungen reagieren. Die Linien werden daher vorerst um sechs Bestücker der NXTIII-Serie von FUJI erweitert, woraus sich eine Erhöhung der Ge­samtleistung um rund 60.000 CPH (Components per hour) ergibt. Es sollen suk­zessive weitere Bestückungslösungen von FUJI folgen.

Die Bestückungsautomaten NXT III von FUJI bilden künftig das Herzstück der SMD-Bestückung bei ETB electronic. Damit wird nicht nur die SMT-Bestückungskapazität ausgebaut und die Produktivität erhöht, sondern auch die gebotene Flexibilität erzielt. Die NXT III ist für die flexible High-Mix-Produktion ausgelegt. Die modulare und skalierbare Lösung eignet sich insbesondere für die Bestückung multi­funktionaler und leistungsstarker Elektronik bei beispiels­weise hoher Bestückungs­dichte von winzigen Bauteilen und vielem mehr. Durch die Skalierbarkeit und einen hohen Grad an Auto­mati­sierung kann sich ETB electronic in Zukunft agil auf neue Markt- und Kundenan­forderungen einstellen.