Artificial Intelligence: How far can you go? 

Altus Group, a leading distributor of electronics assembly equipment in the UK and Ireland, has supported G&B Electronic Designs Ltd., a prominent EMS in the UK, in enhancing its inspection processes through the installation of the Koh Young Zenith Alpha HS+. This advanced True 3D Automated Optical Inspection (AOI) system has strengthened G&B’s already strong commitment to maintaining high-quality standards in PCB assembly. G&B Electronic Designs faced challenges with its previous 2D inspection system, which resulted in difficulties inspecting reflective and increasing complex components. In search of a more effective solution, they partnered with Altus and chose the Koh Young Zenith Alpha HS+. The system addressed these challenges by utilising advanced fully 3D light metrology and proprietary artificial intelligence algorithms to provide precise inspections tailored for modern PCB designs. The system features whole-board foreign material inspection, ensuring contaminants do not compromise assembly integrity, and can inspect components up to 25mm in height. Additionally, its AI-Powered Auto Programming (KAP) streamlines setup processes, reducing programming time and minimising human error. Steve Tumber, Head of Operations at G&B Electronic Designs, said: “Koh Young's reputation for market-leading technology was well-known. After conducting thorough evaluations of key industry players, it became evident that the combination of Koh Young's technology, quality of testing data and Altus's support was the superior choice for our needs.” Joe Booth, CEO of Altus Group, said: “We are pleased to assist G&B Electronic Designs in improving their inspection capabilities. This installation reflects their commitment to quality and continuous improvement, and we believe the features of the Koh Young Zenith Alpha HS+ will provide them with a competitive advantage.” With the integration of the Koh Young Zenith Alpha HS+, G&B Electronic Designs is now equipped to enhance product quality and streamline operations, allowing them to remain competitive in the ever-evolving electronics manufacturing sector.

Artificial Intelligence (AI) has become a major buzzword across industries, yet its true potential and applications are often misunderstood. While AI technologies differ in capabilities, their impact on various sectors is undeniable. The ongoing advancements in AI will likely continue to reshape industries, but how is AI affecting electronics manufacturing today? And what does the future hold? Artificial Intelligence (AI) is increasingly integral to electronics manufacturing, particularly in the transition toward autonomous smart factories within the framework of Industry 4.0. AI technologies are driving significant advancements, transforming the industry and bringing it closer to the vision of smart manufacturing. While certain aspects of this transformation are realised, achieving a fully autonomous "lights-out" factory may still be a distant goal. Nevertheless, AI continues to expand the boundaries of what is possible in this field. The Vision of the Smart Factory The concept of the smart factory has been evolving over the years. While we are seeing tremendous progress, achieving 100% automation remains challenging. In my view, factories will always require some level of human involvement, particularly in the final stages of automation. The first 90% of automation delivers the most value, but the last 10%—the phase that seeks to eliminate all human intervention—will be the hardest to achieve. Despite these challenges, the next 10-15 years will likely see a dramatic transformation in manufacturing, driven by AI tools. These tools already address long-standing pain poi nts and enable process improvements that once seemed impossible. The Smart Manufacturing Vision Pyramid We can look at the 2022 Smart Manufacturing Vision Pyramid to better understand the progress toward the smart factory. This framework highlights the different stages of smart factory development, from basic automation to full autonomy. Many companies have achieved aspects of Smart 2.0, while the technologies associated with Smart 1.0 have become standard practice. The pyramid’s stages are built on key technological advancements, each of which plays a critical role in moving toward full autonomy: 1. Data Acquisition: This foundational stage involves collecting high-quality, accurate, and repeatable data from various sources across the manufacturing environment. Robust data acquisition lays the groundwork for all subsequent stages of smart manufacturing. 2. Insights: Once data is collected, it must be analysed. Statistical analysis and AI-driven insights allow manufacturers to understand their operations better and identify areas for improvement. 3. Digital Twin and Simulation: The next stage involves creating a digital twin—a virtual model of the physical production environment. This simulation can be used to experiment with different variables, such as staffing levels, machine placement, production volumes, and process flow. By optimising these factors in the digital realm, manufacturers can make more informed decisions before implementing changes in the real world. 4. Prediction: AI can predict future outcomes by leveraging both real and simulated data. For example, AI can forecast maintenance needs, enabling predictive maintenance that reduces downtime and minimises the risk of equipment failure. This predictive capability is essential for optimising production and reducing costs. 5. Autonomy: The final stage of the pyramid is autonomy, where machines communicate with each other, make real-time adjustments, and correct errors without human intervention. Examples include autonomous process tuning, automatic calibration, and machine-to-machine communication for seamless production flow. While full autonomy remains a goal, many of these capabilities are already in use today, thanks to pioneers in AI for Surface Mount Technology (SMT) manufacturing. Real-World AI Applications in SMT Manufacturing A leading example of AI in SMT manufacturing comes from Koh Young, a company at the forefront of measurement-based inspection processes. Koh Young’s solutions generate vast amounts of data on products built in SMT lines, which can be leveraged to enhance production quality and efficiency. While valuable on its own, data becomes exponentially more powerful when combined with AI tools like machine learning. For instance, inspection systems rely on test programs with set tolerances to ensure product quality. However, creating these programs can be challenging, especially when limited data is available, as is often the case during New Product Introductions (NPI). Insufficient data can result in weak inspection programs that either fail to catch defects or generate too many false alarms. To overcome this, AI can generate additional data using technologies like Generative Adversarial Networks (GANs) and Convolutional Neural Networks (CNNs). These AI-driven techniques can simulate thousands of products, effectively "training" the inspection system to perform better, even with limited initial data. The result is a more robust inspection process that reduces the likelihood of defects and minimises the burden of false positives on engineers. Another example of AI in action is the optimisation of the interaction between screen printers and Solder Paste Inspection (SPI) machines. Traditionally, SPI systems would inspect solder paste deposits and flag issues for engineers to address manually. However, this process was time-consuming and relied heavily on the engineer’s experience. Today, AI allows SPI systems and printers to communicate directly. The SPI system identifies issues and makes real-time adjustments to printer parameters, such as printing speed and pressure, ensuring optimal performance. This automated feedback loop reduces the need for manual intervention and enhances the overall efficiency of the production line. The Future of AI in Electronics Manufacturing Looking ahead, one AI-driven capability that has the potential to revolutionise production is mounter diagnosis. However, this technology may initially be limited to manufacturers with pre-reflow Automated Optical Inspection (AOI) systems, which require a significant investment. Despite the cost, the benefits are substantial. Mounter diagnosis uses AI to analyse real-time production data and pinpoint the root causes of issues within the mounter, such as problems with the nozzle, head, feeder, reel, or component. By identifying the exact source of a problem, AI enables engineers to address issues quickly, reducing downtime and improving production quality. This capability is particularly valuable in high-volume manufacturing environments, where even minor disruptions can significantly impact overall efficiency. These examples demonstrate that AI is not just a buzzword in electronics manufacturing—it is already delivering tangible benefits. From improving inspection accuracy to optimising machine interactions and diagnosing equipment issues, AI is helping manufacturers move closer to the vision of a smart factory. The Future AI in Manufacturing While the concept of a fully autonomous, "lights-out" factory may remain a distant goal, the advancements we are seeing in AI today are transforming the manufacturing landscape. AI is not something to be feared; rather, it should be embraced for its unprecedented opportunities. Much like we wouldn’t revert to using an abacus instead of a calculator or drawing by hand instead of CAD software, AI is poised to replace many manual, time-consuming tasks. By alleviating the burden of repetitive, labour-intensive work, AI allows skilled workers to focus on higher-level challenges, ultimately driving innovation and efficiency in manufacturing. As AI continues to evolve, the possibilities for its application in electronics manufacturing will only grow. The smart factory of the future may not be completely autonomous, but with the help of AI, it will be smarter, more efficient, and more capable than ever before.

Altus Group, a leading distributor of capital equipment in the UK and Ireland, is pleased to announce the appointment of Ella Gwilliam as their new Operations and Planning Assistant. She will play a key role in further strengthening the company’s capacity to support customers through improved project management and breakdown recovery. Ella brings a wealth of experience to Altus, having previously worked in resource planning within the technology sector. Her background includes close collaboration with customers to assess issues and coordinating with engineering teams to deliver effective solutions. This experience will be invaluable as Altus continues its rapid growth and expands its network of partnerships. Altus has seen sustained growth, with the number of machines supported by the company increasing year on year. The company is adding over 100 new machines annually, servicing both existing and new customers. Ella’s addition to the team is part of Altus’s broader strategy to bolster their operations and planning capabilities, ensuring they maintain high standards of support as their business evolves. “Ella’s arrival marks an important step forward for our Aftersales and Engineering Support teams,” said Mike Todd, Operations and Planning Manager at Altus. “We’re pleased to have her on board, and I’m confident she will make a significant impact on the support side of our business. “At Altus, we set the highest standards for customer service, and efficient operations and planning are vital to ensuring satisfaction, successful project delivery, and quick recovery from breakdowns. With the addition of Ella to the team, we are better equipped to handle the increasing demands as we continue to take on larger, more complex projects with a growing customer base. This is a strong move for our future!” Ella’s ongoing onboarding process will equip her with a thorough understanding of Altus’ processes, so that she is ready to hit the ground running. Her addition represents just one of many new hires aimed at supporting Altus’s continued modernization and growth. www.altusgroup.co.uk.

Danutek Hungary Kft., a leading supplier of capital equipment and service support to the European electronics manufacturing sector, has expanded its technical team to meet the increasing demand for advanced manufacturing solutions. With over a decade of industry experience, Zoltán Dávid joins the team to enhance service capabilities in the fast-evolving areas of coating, dispensing, and X-ray technologies. This expansion aligns with Danutek Hungary's continued growth, particularly in dispensing technologies, supported by its strong partnership with Axxon Mycronic, a leading global supplier of dispense and conformal coating systems. As this partnership strengthens, more systems are being installed across the region. Roland Losonczi, Technical Support Manager at Danutek Hungary Kft., said: “Finding the right person to join our team is critical for Danutek, as we hold ourselves to high standards. Technical knowledge is essential, but equally important are cultural fit and work ethic. While we are proud of our exceptional brands, the way we support our customers throughout the lifecycle of their machines is vital for securing repeat business. Zoltán has already proven to be a valuable addition, and I look forward to seeing how he continues to grow within our team, enhancing our ability to support end users.” Zoltán’s addition comes in response to key industry trends, including the rising adoption of advanced dispensing systems across various electronics manufacturing sectors. At the same time, the demand for high-precision X-ray inspection solutions—such as X-ray counters, Batch 2D X-ray, Inline AXI X-ray, and CT X-ray units—has significantly increased. These developments have created a need for specialised technical support in implementing and maintaining these innovative technologies. Danutek Hungary Kft. is at the forefront of advancements in the electronics industry. By expanding its technical team, the company demonstrates its commitment to providing effective solutions and exceptional support throughout the entire lifecycle of its equipment.

Altus Group, a leading distributor of capital equipment in the UK and Ireland, in partnership with Fuji Corp., recently held its second ‘Factory of the Future’ event at the Advanced Manufacturing Technology Centre (AMTC) in Coventry. The two-day symposium marked a significant milestone as the largest event ever organised by Altus, showcasing the latest advancements in electronics manufacturing. Building on the success of its inaugural event in 2022, this year's ‘Factory of the Future’ attracted over 200 participants and featured nearly 30 suppliers, offering hands-on experiences with nearly 40 unique processes. This expanded scale allowed attendees to explore a comprehensive range of technologies essential for SMT, NPI, and through-hole production lines, as well as component management and peripheral production. The event introduced several innovations to the UK market for the first time, including the Scienscope Xspection 3000 Batch Xray, the Inertec Cube 460 selective soldering unit, the Koh Young Neptune Conformal Coating Inspection System, actnano's disruptive coating materials, and the YJ Link vision inspection buffer. Joe Booth, CEO of Altus Group, said: “What an incredible few days! Organising an event of this scale is a monumental effort, and the Altus team truly outdid themselves this time. The positive feedback from our customers and partners has been exceptional, and having over 200 participants is a clear indicator of our growing presence in the UK and Ireland. We’re excited to build on this momentum and turn the interest from the event into successful projects in the months ahead.” Artur Tobolski, Fuji Regional Account Manager, said: “The Factory of the Future event was a tremendous success, bringing together top industry leaders and showcasing the latest innovations. It gave UK manufacturers a unique opportunity to engage with cutting-edge technology and gain insights into future trends. Fuji is proud to have partnered with Altus for this landmark event and looks forward to continuing our collaboration with the industry.” The comprehensive program included 16 presentations from industry leaders, addressing several topics, including the future of electronics manufacturing and current industry trends and challenges. The timing of the event was particularly opportune, coinciding with a notable increase in capital equipment investment following the new government's election, which has contributed to enhanced stability and growing manufacturing demand. www.altusgroup.co.uk

Altus Group, a leading distributor of capital equipment in the UK and Ireland, has introduced an advanced BGA re-balling solution to address the electronics industry's growing focus on sustainability and cost-efficiency. Developed by their pre-eminent supplier, Essemtec, this innovative process offers manufacturers a new approach to component recovery and reuse, aligning with increasing market demands for environmentally conscious practices. Building on their expertise in adaptive SMT equipment, Essemtec has designed a cutting-edge BGA re-balling process that consolidates flux deposition, ball placement, and soldering into a single streamlined solution. This all-in-one approach is particularly advantageous for high-volume OEMs and companies in sectors such as military, aerospace, computing, and communication, providing a cost-effective and sustainable method for component recovery and reuse. Jiri Kucera, Operations Director at Altus Group, said: "Reworking BGAs, recovery of expensive parts, and re-use is becoming a highly discussed topic across the electronics industry as consumers become more interested in sustainability. This is another example of Essemtec developing a process to meet the needs of the market." The new robotic process offers several advantages over traditional manual methods: 1. Increased precision and reliability. 2. Support for various ball sizes (250 µm to 1 mm+) and materials. 3. Improved success rates compared to manual stencil techniques. 4. Cost-effective reuse of expensive BGA components. Jiri added, "Companies are already using the Essemtec jetting unit for BGA re-balling across a range of pitched components, giving partners the power to bring some of the recovery processes back in-house rather than outsource to partners at a higher cost." This solution is particularly relevant for organisations prioritising environmental impact and sustainability. By extending the lifecycle of electronic components, the process contributes to waste reduction and promotes a more circular economy in electronics manufacturing. Altus sees this technology as a significant step in meeting the electronic industry's evolving needs. As sustainability continues to gain importance, solutions like this will play a crucial role in shaping the future of electronics manufacturing and repair. www.altusgroup.co.uk.

Altus Group, a leading capital equipment distributor for the electronics industry in the UK and Ireland, is pleased to announce the addition of a Senior Sales Manager to its growing team. With this appointment, Altus strengthens its sales force, now comprising of a six-person strong Sales Team. Matthew Fitzpatrick, who will cover the north of the UK, brings a wealth of experience in account management and new business development, having successfully managed large-scale, technical projects in adjacent sectors. His expertise will be instrumental in enhancing Altus’ account management capabilities and expanding partnerships across the Northern region, where the electronics manufacturing sector is thriving. “I am very pleased that we can bring someone of Matt's calibre into our organisation,” said Joe Booth, CEO of Altus Group. “Matt has a proven track record of adding value to customer experiences and exceeding performance targets makes him a valuable addition to the team. “With the North of the UK being a critical hub for electronics manufacturing, Matt’s expertise will be instrumental in supporting our suppliers and customers in the region. As he transitions into his role, I am confident that Matt will continue our momentum in driving growth, while also ensuring that our existing partners receive the exceptional service they have come to expect from Altus.” The addition of Matthew reflects Altus’ commitment to providing the highest quality pre-sales and after-sales care. The company's partner list has grown exponentially over the past five years, and with increased capacity in pre-sales and account management, Altus ensures that customers receive exceptional project support, which is a significant reason for the growth they have witnessed. Matthew added: “I’m excited to join Altus and eager to get started. The company’s clear mission to set new benchmarks in customer service is both inspiring and contagious. Altus already supports an impressive range of customers and works with industry-leading suppliers, which makes this role all the more appealing. I’m eager to dive into the technology and see how I can contribute to Altus' continued success.” Matthew will undergo an extensive on-boarding process over the coming months, preparing him to support key accounts. Customers and suppliers will have the opportunity to meet him in person at Altus’ upcoming Factory of The Future taking place in September. www.altusgroup.co.uk.

Altus Group, a leading supplier of capital equipment for the electronics manufacturing industry in the UK and Ireland, is pleased to announce the successful installation of a second Koh Young Zenith 3D Automated Optical Inspection (AOI) system at Active-PCB Solutions. This latest investment highlights Altus’ commitment to providing innovative solutions that enhance operational efficiency and quality in the Electronics Manufacturing Services sector. Active-PCB Solutions, a leading contract electronics manufacturer, previously invested in the Koh Young Zenith Alpha HS+ AOI two years ago, achieving outstanding results with the initial system. Pleased with its performance, the company has now expanded its capabilities by adding a second unit. This new investment will further enhance their inspection processes, enabling comprehensive 3D inspection and meeting the demanding standards of modern electronics manufacturing. Luke Minnis, Manufacturing Product and Process Engineer at Active-PCB, said: "I have been a Koh Young and Altus partner for many years now, and we are really happy to keep building on our partnership and to bring in another 3D AOI. This investment is a clear sign of our ambitions for the future and our desire to implement the best-in-class processes at our facility." Anthony Oh, Technical Applications Manager at Altus Group, said: "It is always gratifying to receive repeat orders from our partners. This ultimately means the machine is generating the expected return on investment they had planned. Active-PCB is a significant player in the UK CEM space, so to have their continued trust and investment is something we are very proud of. We look forward to continuing to support them as they leverage the AOI platform to drive further improvements in their manufacturing processes." The Koh Young Zenith Alpha HS+ is known for its high-speed, AI-driven 3D measurement capabilities. With a 4-projector setup using Digital Light Processing (DLP) technology, the system offers 15-micron resolution and full 3D metrology up to 25mm in height. These advanced features ensure precise and reliable inspection of complex assemblies, meeting rigorous quality standards. www.altusgroup.co.uk.

Altus Group and its sister company Danutek, renowned suppliers of capital equipment and service support to the electronics manufacturing sector, are pleased to announce their new partnership with actnano, a global leader in surface protection technologies. This collaboration aims to bring actnano’s cutting-edge Advanced NanoGUARD (ANG) coatings and other functional materials including permanent anti-fog, lubricants, and sealants to a broader audience across Europe. actnano is at the forefront of coatings technology, providing fluorine-free, thin-film coatings that offer exceptional protection against water damage and harsh environmental conditions. Their innovative solutions, which require no masking or curing ovens, significantly reduce the capital expenditure, floor space, and energy consumption associated with traditional coating methods. Joe Booth, CEO of Altus Group, said: "actnano exemplifies the ideal partner for Altus and Danutek in our regions. Their approach, deep market understanding, and clear value proposition are truly impressive. Their unique product addresses critical pain points with a quantifiable ROI, making it highly attractive to customers. actnano's proven track record of securing business with major global brands and their strong references speak volumes. Initially, the concept of no masking and no curing ovens seemed almost too good to be true. However, their Munich lab, designed to support customers through technical validation, quickly demonstrated that this technology is just as ground-breaking in practice as it is in theory. actnano's innovation is not just exciting; it's revolutionising the industry." "actnano is proud to work with Altus and Danutek, whose team has consistently earned customer trust by introducing cutting-edge technologies like Koh Young’s 3D AOI and LPKF’s laser depaneling to the European market. Their expertise in this area will make them a valued partner as we continue to expand across the region," said Sruti Balasubramanian, VP of Product Development at actnano. Nic Johansen, actnano Director of Sales, commented, “Altus and Danutek excel in the regions they operate in, including their support for leading dispensing processes like PVA and Mycronic—making them a great match for us. This partnership accelerates our ongoing efforts across Europe with OEMs and manufacturers, and extends our reach and local support, especially in the UK and Eastern Europe, key areas for nearshoring and reshoring. Together, we're dedicated to driving the industry forward with innovative solutions, expert guidance, and a primary focus on customer success. The best is yet to come.” actnano’s technology is particularly noteworthy due to its ability to simplify the application process by eliminating the need for masking and curing ovens. This innovation helps avoid common issues such as cracking and bubbling, which are prevalent with traditional methods. Furthermore, by reducing the need for extensive machine investment and floor space, and decreasing energy consumption over the product lifecycle, actnano provides a cost-effective and efficient solution for electronics manufacturers. Their high protection standards offer up to IPx8 protection levels, applicable to full PCBA including connectors, antennas, LEDs, and high-heat generating components, while ensuring environmental safety with fluorine-free coatings. www.altusgroup.co.uk.