The Importance of Top-Quality Distribution Partners in Achieving Manufacturing Excellence

Altus Group, a leading distributor of advanced electronics manufacturing equipment in the UK and Ireland, will showcase a selection of cutting-edge solutions at Southern Manufacturing and Electronics 2025 from 4-6 February at the Farnborough International Exhibition Centre. Visitors can learn about innovative technologies tailored to meet the evolving demands of the electronics industry at the stand, and gain valuable insights into industry trends and strategies for modernising operations during a seminar hosted by the company. Joe Booth, CEO of Altus Group, will present a session on Tuesday 4 February, titled ‘Every Challenge is an Opportunity with the Right Vision.’ The presentation will cover key trends of 2024, offering strategies for manufacturers to modernise and automate operations in order to remain competitive in a shifting market. Joe will also share insights on adapting to industry challenges and future-proofing manufacturing processes. ‘’I can’t wait for this years’ Southern Manufacturing event!” said Joe. "As a one-stop shop for electronics production, selecting what to showcase from our full range of solutions is always a challenge. However, we’ve carefully chosen four of our best-performing suppliers and processes from 2024, which address key industry challenges that the market is actively exploring. “At the event, we’ll be demonstrating these solutions in action. We’ll also be unveiling our brand-new product brochure, featuring the latest innovations from our suppliers. But more importantly, we’re eager to hear directly from our customers about their pain points for 2025 and how we can help solve them. Last year, the event generated the most leads and meetings we’ve ever had, and we’re looking forward to achieving the same success this time around." Altus will showcase a selection of advanced equipment including the Koh Young Alpha HS+ 3D Automated Optical Inspection (AOI) System. This cutting-edge system uses AI-powered precision to inspect pcbs with unmatched accuracy, reducing the need for manual inspection and improving process yields. The Alpha HS+ is designed to help manufacturers maintain the highest quality standards while driving production efficiency. Another highlight will be the PVA Delta 8 Conformal Coating and Dispensing System, a versatile solution for coating, potting, and dispensing applications. Known for its reliability and precision, the Delta 8 is ideal for high-mix production environments where consistency and flexibility are key. Altus will also feature the Essemtec Fox ‘All in One’ System, a modular pick-and-place system that offers scalability for manufacturers working with high-mix, low-volume production. The Fox system’s small footprint and expandable design make it a perfect fit for space-constrained production lines. Finally, the Scienscope AXC-800 III X-ray Component Counter will be on display. With an accuracy rate of 99.99%, this system helps manufacturers streamline inventory management by providing fast and precise component counting, reducing downtime and enhancing overall efficiency. For 2025, Altus Group will also introduce a brand-new stand design, offering an updated experience for visitors to learn more about the innovative solutions on display. Visit Altus Group at the Southern Manufacturing & Electronics Show 2025, stand J80, from 4-6 February 2025 at the Farnborough International Exhibition Centre.

Altus Group, a leading distributor of capital equipment in the UK and Ireland, has successfully helped G&B Electronic Designs Ltd., a prominent contract electronics manufacturer, address a key operational challenge by supplying the Scienscope AXC-800 III X-Ray Component Counter. This strategic investment enables the company to further enhance and optimise production efficiency. G&B Electronic Designs, with over 40 years of experience in delivering high-quality electronics assembly services, was facing inefficiencies due to its manual component counting process. The company’s high-mix, low-to-medium volume production environment, combined with frequent production changeovers, made it critical to find a solution that could streamline operations and improve traceability. Recognising these challenges, Altus worked closely with G&B to identify the Scienscope AXC-800 III as the ideal solution. The system offers advanced X-ray technology capable of counting up to four small reels in less than 30 seconds, helping to increase G&B’s component handling and improving accuracy. Joe Booth, CEO of Altus Group said: "We recognised that G&B needed a solution to eliminate the bottlenecks caused by manual component counting and reduce the risk of shortages. By working together, we were able to identify the Scienscope AXC-800 III as the perfect fit for their needs. The system has not only sped up the component counting process but also enhanced traceability, offering them a robust tool to manage their inventory more efficiently." The AXC-800 III’s features, including real-time barcode scanning, automated label printing, and seamless integration with Manufacturing Execution Systems (MES), provide G&B with enhanced control over their stock and eliminate risks associated with manual processes. Darren Bills, Purchasing and Materials Manager at G&B Electronic Designs, said: "G&B is always evaluating ways to improve its processes, not just in assembly but across the entire business, so that we are always moving forward and developing. We have been focusing on internal efficiencies, including our factory layout, process flow, component storage area, and now our automatic component counter. These changes have been paying dividends in terms of increased productivity and reduced errors.” Since installing the Scienscope AXC-800 III, G&B has seen immediate improvements in its production cycle. The automated system has significantly reduced component counting times, allowing the company to quickly check kits and book stock back in from production, minimising downtime and the risk of line shortages. This is the second major project between Altus and G&B in 2024, highlighting their strong working relationship. By consistently finding innovative solutions, Altus has helped G&B remain competitive in the electronics manufacturing sector, meeting today’s demands while preparing for future growth.

Altus Group, a leading distributor of capital equipment in the UK and Ireland, emphasises the importance of reducing voids in reflow soldering to improve manufacturing efficiency and product reliability. As one of their key suppliers, Heller Industries, a global provider of electronic manufacturing reflow solutions, has developed multi-stage controlled vacuum technology that reduces void rates to below 1%. This technology is especially beneficial for industries like semiconductor and surface-mount technology (SMT) assembly, where maintaining high-quality solder joints is crucial. With the increasing demand for high-performance electronics, reducing voids in solder joints is essential for ensuring long-term reliability. Heller’s vacuum-assisted reflow soldering process has proven to significantly reduce void rates by up to 99% while addressing substrate and wafer warpage, critical challenges for the electronics manufacturing industry. Heller’s vacuum technology creates a controlled vacuum environment during the reflow process, allowing gas bubbles to escape, reducing void formation. This results in improved heat dissipation, better product stability, and enhanced performance, particularly in high- frequency applications. Additionally, the technology helps eliminate solder splatter and prevents solder bridging, further improving manufacturing efficiency. Joe Booth, CEO of Altus Group, said: "We are lucky to have suppliers that are dedicated to developing solutions that make a real difference for our customers and voiding is top of mind for many globally. Heller's multi-stage controlled vacuum technology advancements are a perfect example of a supplier addressing a trend, offering manufacturers a way to improve solder joint quality and eliminate issues like voiding whilst mitigating warpage. By helping customers optimise their reflow soldering processes, we’re enabling them to achieve higher quality products and more efficient operations.” Heller’s vacuum-assisted reflow technology, now widely implemented across customer installations in production, offers manufacturers a cost-effective solution with high efficiency and low unit per hour (UPH) rates, making it ideal for optimising production without compromising quality. Altus in partnership with Heller are a significant force in the electronics manufacturing industry, helping manufacturers address key convection reflow process related challenges. Through its ongoing collaboration with Heller Industries, Altus is supporting over 200 manufacturing sites in the UK using Heller to improve process reliability, product quality, and operational efficiency, further reinforcing its role as a trusted industry partner. www.altusgroup.co.uk.

Altus Group, a leading distributor of capital equipment in the UK and Ireland, has announced the return of Gareth Cuthbert as Application & Service Engineer to its team, reinforcing the company's commitment to supporting excellence and customer service. Gareth previously worked with Altus for nearly six years, during which he gained an understanding of the company’s processes, platforms, and customer needs. Since then, he has expanded his skillset as a service engineer for a world-leading filtration provider, gaining valuable insight into delivering exceptional on-site solutions. Mike Todd, Altus Senior Operations and Planning Manager said: "We are really pleased to welcome Gareth back to the Altus team. His familiarity with our systems and customers will significantly reduce the onboarding time and allow him to contribute quickly. His expanded experience working closely with customers in his previous role aligns perfectly with our commitment to providing outstanding support. Bringing Gareth back enhances our technical expertise on inspection products and strengthens our presence in the North, a region where we see sustained growth opportunities.” Altus Group has experienced remarkable growth in recent years, almost tripling its customer base over the last five years by consistently acquiring new clients. With a steadfast focus on aftersales excellence and ongoing customer care, the company is investing in its service capabilities to meet growing demand. Gareth’s reappointment represents another strategic step in ensuring customers receive unparalleled support. Based in Barnsley, Gareth will undergo an intensive training and accreditation programme to ensure he is equipped with the latest knowledge and skills. Customers in the North can expect to see Gareth actively supporting maintenance and breakdown services starting in January 2025. www.altusgroup.co.uk.

Altus Group, a prominent distributor of advanced equipment for electronics assembly in the UK and Ireland, has announced its participation in the Southern Manufacturing & Electronics show, held from 4-6 February 2025 at the Farnborough International Exhibition Centre. This event brings together industry leaders and innovators, offering an ideal platform for Altus to present a range of technologies designed to meet the increasing demands of electronics manufacturing. Among the advanced solutions on display will be the Koh Young Alpha HS+ 3D Automated Optical Inspection (AOI) System, known for its whole-board foreign material inspection, high precision, and AI-powered functionality. The Alpha HS+ streamlines setup and operation, ensures no escapes, and ultimately allows its users to drive up their production yields, making it an invaluable resource for the best in PCBA manufacturing. Joe Booth, CEO of Altus Group, said: “We are pleased to once again exhibit at the Southern Manufacturing & Electronics Show, a key event for the industry. We are uniquely placed as a one stop shop provider for almost every process in PCBA manufacturing, so the to show gives us a great opportunity to speak with prospective customers, who we tend to have one solution or an entire process that is relevant. For me the show offers a brilliant opportunity for the market to come together, for us to understand the needs of both our customers and prospects, and for us to demonstrate what are the most popular process upgrade opportunities and why.” Altus will also showcase the Promation 9544CJ Pro Robotic Soldering Unit after a record year of sales in 2024. Built for precision, this system features a high-stability hot iron soldering capability. With an innovative design that improves flux core outgassing and minimises solder defects, the 9544CJ Pro enhances reliability in high-volume production environments. The PVA Delta 8 Conformal Coating/Dispensing System will also be demonstrated at the event. Engineered for selective coating, potting, and dispensing, Delta 8 is ideal for various complex assembly processes. Its robust overhead three-axis motion platform and closed-loop process control provide consistent and precise operation, setting a high standard for precision in manufacturing. Also on display will be the Scienscope AXC-800 III X-ray Component Counter after another big year of installations regionally. This third-generation system offers an innovative approach to component inventory management, delivering accurate counts in seconds with an impressive 99.99% accuracy rate. Its integrated optical barcode scanner accelerates data capture, making it an essential tool for fast-paced production lines. Visit Altus Group at the Southern Manufacturing & Electronics Show 2025, stand J80, from 4-6 February 2025 at the Farnborough International Exhibition Centre. www.altusgroup.co.uk.

Altus Group, a leading distributor of capital equipment in the UK and Ireland, has seen an increasing interest in laser depaneling systems from LPKF in 2024. Laser depaneling is an advanced method for separating PCBs from their panels using precise laser cutting technology. This innovative process offers significant benefits in efficiency and versatility, making it increasingly relevant across various manufacturing sectors. Laser depaneling has emerged as a superior alternative to conventional separation methods. It allows for stress-free, non-contact separation, enabling cuts to be made close to mounted components without damaging them. The precision cutting with narrow channels, combined with the flexibility to process various materials—both rigid and flexible—makes it a highly efficient solution for electronics manufacturers. Especially those that are looking for cost saving on their bill of materials, as using a laser can significantly reduce the amount of PCB needed for break out areas providing material and immediate ROI. This digital, software-based and laser beam guided method accommodates complex geometries while eliminating tool wear, significantly reducing maintenance and changeover costs. Joe Booth, Altus Group CEO, said: "We've seen growing interest in LPKF laser depaneling solutions, particularly the CuttingMaster 3000 series with Tensor technology. Manufacturers are increasingly recognising the benefits of this advanced approach to PCB separation. The precision, flexibility, and efficiency offered by these systems allows our customers to stay competitive in demanding industries such as automotive, medical technology, and consumer electronics where accuracy is key." The LPKF CuttingMaster 3000 series is recognised as one of the most flexible and precise laser depaneling systems on the market. Equipped with linear drives, these systems ensure exceptional positioning accuracy and high-quality results with a large working range. These systems can integrate a wide variety of laser sources with different wavelengths and pulse widths in the nano or picosecond range. Many of the models also feature LPKF's advanced Tensor technology, making them suitable for a diverse range of applications and materials. This ultrafast beam deflection technology offers up to a 70% reduction in cycle times when combined with LPKF CleanCut. It significantly increases performance potential while maintaining maximum transmission and high robustness for excellent reliability, improving cost efficiency. As the complexity of electronic devices continues to increase, Altus sees laser depaneling as an important technology for manufacturers looking to enhance their production capabilities. www.altusgroup.co.uk.

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.