Zollner Elektronik AG automates THT assembly in the E3 business unit with sFAB-D from FUJI

Kelsterbach, June 7th, 2021 – Zollner Elektronik AG has set the course for the future. At the Romanian site Satu Mare, Zollner is integrating two state-of-the-art modules for the automation of THT assembly in the E3 business area. The sFAB-D placement machines with Cut & Clinch Conveyor from FUJI EUROPE CORPORATION (www.fuji-euro.de) ensure reliable processes, guarantee efficient line configuration and increase the output in the production of assemblies for industrial electronics.

Zollner Elektronik AG is a globally established service provider for Electronics Manufacturing Services (EMS) and the market leader in Europe. Zollner offers complex mechatronic solutions for various application areas and industries such as automotive, telecommunications, industrial electronics, data, railway and measurement technology, aviation and defense as well as healthcare and life sciences. The partner for process and system solutions supplies its customers with individual electronic components, modules, devices and systems.

Ferenc Fiausch, Sales Engineer at FUJI EUROPE CORPORATION GmbH, explains: “At Zollner Elektronik AG, an automated solution in the area of THT assembly – Through Hole Technology – was required for the electronics production E3S in Satu Mare in Romania. In the manufacturing process of THT assembly, the connection wires of the components are inserted into the corresponding vias on the circuit board and then soldered. This push-through installation is extremely complex if done manually. “

In order to gain efficiency in this process and to be able to meet increasing customer needs and constantly new requirements, Zollner chose the sFAB placement machine from FUJI. FUJI EUROPE CORPORATION GmbH is an international operating specialist for electronic placement machines. The German branch of FUJI CORPORATION distributes sFAB-D and other assembly machines for the European area.

Efficient process automation and more security

Two sFAB-D machines with Cut & Clinch Conveyors are now used in the Zollner production line in Satu Mare. The company is thus able to automate processes efficiently, adjust the type or quantity of production with a flexible line configuration and achieve quality and delivery improvements for every production process. Recurring costs can also be reduced in the long term.

The sFAB-D with Cut & Clinch Conveyor enables Zollner to handle assemblies without errors. The placement modules are equipped with a clinching tool, which among other things increases the safety when handling the assemblies. The placement modules are currently operating as a stand-alone line. In the medium term, they are to be combined as an inline solution with an existing soldering system. In order to automatically collect trace data in the future, it is also planned to be integrated into the Manufacturing Execution System (MES).

Sascha Frieling, Technology Manager at FUJI EUROPE CORPORATION GmbH, says: “One of the goals of Zollner Elektronik AG was to increase production output by investing in our sFAB-D line, to reduce costs and maintain the quality standard. This has been achieved. Furthermore, the company is now able to keep all processes and costs transparent and measurable.”

Electronics service provider aims for best possible throughput and high quality through optimized processes

Kelsterbach, March 9, 2021 – The EMS service provider KATEK GmbH has chosen to implement the NXTR-S smart factory platform from FUJI EUROPE CORPORATION GmbH (www.fuji-euro.de) at its Grassau site. FUJI is an internationally active specialist for electronics placement machines and offers with NXTR a platform that serves the step-by-step automation and digitalization in electronics manufacturing. NXTR-S aims to optimize the feeders already in use and is the basis for the best possible throughput. By using the smart factory solution, KATEK is focusing on high productivity and quality through optimized and digitized processes.

KATEK GmbH is one of the largest electronics service providers (EMS) in Germany. At the production sites in Grassau and Györ (Hungary), highly automated large-scale production orders, among other things, can be carried out on the basis of all common certifications. The company relies on process automation in various areas for the benefit of efficiency and high quality. For this reason, KATEK GmbH has decided to install the NXTR-S smart factory platform from FUJI EUROPE CORPORATION at its Grassau site.

Designed by FUJI as an evolution of the proven NXT series (scalable placement platform), the NXTR is designed to free operators from repetitive tasks – while maximizing quality and productivity. The NXTR follows the “3 Zero” strategy: zero placement errors, zero machine operators, zero machine stops.

High savings potential through optimization of existing feeders

The NXTR-S is the first expansion stage of the Smart Factory platform. It relies on new Multi Feeder Units that facilitate and optimize feeder operation. The Manual Mode uses the feeders that are currently already in use at customers of FUJI EUROPE CORPORATION GmbH. This has the advantage that no generation change of feeders is required, resulting in a high savings potential.

In addition to the unique features that mark the FUJI products NXTR-S and also NXTIII – such as the one-side operation, exchangeable heads and much more – the following features in particular tipped the scales in favor of the NXTR-S:

• Increase in productivity due to better exchangeable MFU 52
• Number of feeder slots on NXTR-S is higher than on NXTIII
• Larger PCB size
• Compatibility of existing NXTIII feeder
• Part presence control and touchdown sensor
• Expectation of higher quality and more productivity on NXTR-S compared to NXTIII
• LCU features (remote control, self-diagnostic function, response to network problems, and more)

The solution will be installed at KATEK in spring 2021.

“Our Smart Factory platform NXTR-S is in constant development and our goal is to modify it to NXTR-A – meaning an automated solution with Smart Loader – within the next two years. In this way, we are taking further important steps towards the optimization of production preparation and maintenance processes as well as the automation of manual assembly processes in terms of comprehensive networking and self-optimized production,” explains Sascha Frieling, Manager Technology at FUJI EUROPE CORPORATION GmbH.

Speziallösungen von FUJI werden in Deutschland gefertigt und getestet – dies gewährleistet hohe Effizienz und Prozesssicherheit

FUJI EUROPE CORPORATION offers special solutions for individual and efficient placement processes

15th April 2020 – The placement of special parts (Odd-Form) requires fast and reliable solutions in the European market. FUJI EUROPE CORPORATION GmbH (www.fuji-euro.de) therefore has a department for special solutions such as special nozzles, mechanical chucks and special feeders integrated in the German branch. This ensures extensive testing on site and fast deliveries due to short distances.

Stefan Janssen, assistant general manager of FUJI EUROPE CORPORATION GmbH, explains: “Odd-Form components have special process requirements. Therefore, we need customer specific solutions. The demand in this area is very high. Thanks to our on-site department in Kelsterbach, we can offer very short delivery times. The special solutions are also thoroughly tested in our company, which guarantees a high level of process reliability”.

Special nozzles, mechanical chucks and Special feeders

Special solutions from FUJI include special nozzles, mechanical chucks, and special feeders. “The special or custom nozzles are used for picking up components on all types of heads that cannot normally be picked up with a standard nozzle using vacuum. Special nozzles are manufactured individually and are specially designed for a component. FUJI therefore has a global database in which the appropriate templates can be accessed. In this way individual solutions can be implemented quickly,” explains Stefan Janssen.

Mechanical chucks are also part of FUJI’s portfolio. They are used to pick up components on the H01, H02 or S1 head. They are used to pick up components on the H01, H02 or S1 head. These cannot usually be picked up with a standard or special vacuum nozzle.

The company has developed extensive special solutions in the field of special and customized feeders. These feeders are used to feed components to SMT placing machines. FUJI manufactures punch feeders and bowl feeders as well as complete component assembly solutions for this special purpose.

Individual, overall automation solutions

FUJI’s special solutions are based on in-house developments combined with standard components. Highly specialized automation processes are realized with individual hardware and software solutions. “FUJI is an experienced and highly specialized partner in special machine construction and automation. Even with very complex requirements and linkages, we are able to offer integrated individual solutions,” explains Stefan Janssen.

Kompakte Maschine für die Backend-Automation –
extrem schnelle Handhabung von Axial-/Radial-Bauteilen und Jumper

Assembly processes at high speed: New sFAB-Alpha from FUJI EUROPE CORPORATION

Kelsterbach, 27th. February 2020 – The automation of processes after the SMT phase can now be implemented at very high speed. FUJI EUROPE CORPORATION GmbH has launched a new multifunctional placement platform for this production phase: The sFAB-Alpha combines the functionality of three machines in one and supports the integrated handling of several types of parts. It efficiently assembles axial/radial components and jumpers. The sFAB-Alpha takes up little space, reduces workload and ensures faster changeover times.

FUJI EUROPE CORPORATION GmbH, specialist for highly flexible placement systems in high-mix up to complete placement lines in high-volume, presents with the sFAB-Alpha a new innovation for backend automation. The mixed placement platform enables the integrated handling of several part types (radial parts, axial parts and jumpers) in one compact machine. This 3-in-1 principle increases utilization, saves time for changeover as well as space and installation or operating costs.

All-in-One-Solution for fast automated processes

The compact sFAB-Alpha requires only 25 percent of the space of a conventional machine. It is designed to automate manual assembly work and at the same time achieve high productivity and top quality. It offers immediate support for variable mix or variable volume production. The platform works with freely combinable parts supply units. The required units are set up according to production requirements. This significantly reduces the amount of work involved. Shorter and more efficient changeover times are also possible.

“The main reason for machine stops is the replacement of parts. If part types need to be replaced, the process can take a considerable amount of time. The sFAB-Alpha supports offline exchange and stack exchange of feeders. This makes it possible to change the feeders in a batch using the feeder carriage feeding method. In this way, parts can be exchanged in the shortest possible time. In addition, the speed of processes can be significantly increased by optimizing the cycle balance in the line,” explains Stefan Janssen, Assistant General Manager of FUJI EUROPE CORPORATION GmbH. The sFAB-Alpha communicates with the Nexim software system provided by FUJI. Since it is possible to use shared panel and parts data, the time required for order creation can be reduced.