We implement complex EMS projects from the purchase of components to the delivery of the product to the required address
At the beginning of the production cycle, each production unit receives a unique 2D bar code that is connected with this unit throughout the entire production process. All operations performed on the relevant product unit within the whole production process are recorded; using this unique code; in case a discrepancy is detected, within a few moments our operators are able to trace a faulty process and take actions to rectify the situation.
Employees of the sales department are ready to respond flexibly to all customer requirements. We retrospectively evaluate satisfaction with the progress of orders with the aim of continuous improvement of our services.
Our team of experts is prepared to find optimized solutions for your product in terms of manufacturing/costs. Our design team works to provide a PCB layout according to schematics and associated Net List provided by customer`s engineers or alternatively our design engineers are ready to provide a full turnkey integrated electronic design and layout.
In order to make our production of the highest quality and the most efficient, we pay attention to carefully prepared prototypes and sample production along with testing. A prototype or test sample is a working model of an electronic device that comes as close as possible in functionality, size, and other parameters to the product that will be mass-produced. TOROLA works closely with customers on prototype builds to not only deliver needed units but to also look ahead to determine the following product’s attributes before the initial batch is manufactured. Efficiency, cost optimization, and guaranteed outcome are the hallmarks of SMT’s sample manufacturing operations.
According to the customer-supplied production documents, the purchasing staff will provide all the necessary material. The customer may provide the material himself.
The supplied material is received by Incoming Material Inspection where our controllers check, confront and eliminate all material disagreements. As an element of the TOROLA electronic quality policy, we inspect all incoming material to provide a flawless start of the production process. This is to eliminate misunderstandings between the Company and its suppliers, facilitating interchangeability, and improvement of products.
All checked components are stored in racks and registered into our information system by warehouse employees. We pay close attention to the storage conditions of all materials. While respecting the principles of FIFO (First In, First Out), the warehouse employees remove the material from its storage based on a production order. We are able to re-identify the entire history of a product or its parts using a production traceability application developed in-house, together with a laser-burnt 2D code on each PCB and a reader with a terminal located at each workplace.
For the PCB assembling process we utilize two SMT mounting lines. The PCB assembly consists of 4 main processes.
1. OFF-LINE SMT WORKPLACE PREPARATION
Every component undergoes thorough inspection in our Offline Work-place. Part numbers, tolerance, values, quantities and all other variables are checked against the Material Checklist, documentation provided by supplier and our own internal part database to ensure full compliance and conformity to all specifications required. After all parts have been received and verified package programming begins to ensure proper placement on the PCB.
2. STENCIL PRINTING
After all components have been programmed, solder paste is applied to each board on the Stencil Printer GKG JUKI GL PLUS, the first unit in our SMT line. It’s engineered for continuous high value printing of a flawless product. A two ways automatic dry/wet/vacuum stencil wiper allows user to select any combination of cleaning mode. Flexible Automatic Clamping System is uniquely designed by GKG and it combines retractable top clamp and motor controlled side clamp. A LED light source providing illumination from the top utilizes a camera to detect any clogged stencil and ensure the accuracy of the print head and shuttle assembly.
3. AUTOMATIC ASSEMBLY MACHINES
Components are placed on the printed circuit board via the Pick and Place Machine. TOROLA utilizes two High-Speed Flexible Mounters – JUKI KE2080L and KE2070L. The ultra-flexible KE-2080 can place a wide range of components from 0402 (01005) and ICs, to odd-form. The new LNC60 laser head is capable of picking and centering 6 components simultaneously. The LNC60 sensor has the unique ability to center components from 0402 (01005) to 33.5mm square parts. From ultra-small, ultra-thin, chip-shaped parts to small QFP, CSP, BGA, a wide range of parts can be mounted by the laser recognition system at high-speed and with high-accuracy.
4. REFLOW OVEN
At the end of our SMT line is Heller Industries’ reflow oven HELLER 1707 EXL.
The 1707 EXL supports high mix / medium volume throughput… at speeds up to 24 inches (60 centimeters) per minute, while conserving valuable factory floor space. Rapid response times and precise temperature controls assure process uniformity, regardless of component density or board loading, with identical profile performance in either air or nitrogen. The Model 1707 EXL combines sophisticated design elements with the engineering expertise and reflow technology leadership from Heller Industries. The most efficient heat transfer from extra high volume, high-velocity, heating modules, producing heater module response of less than one second to temperature changes of less than 0.1°C, thereby maintaining profile integrity for heavy board loads.
Both our SMT Assembly lines are fully computerized. Each piece of equipment is characterized by extreme accuracy, high throughput and maximum control.
We have invested in a several solutions to meet THT (Through-hole
technology) requirement from single sided THT assemblies to complex high
mix SMT and THT assemblies.
The manufacturing requiring Through Hole Assembly Services is done at workplaces for shaping and manual mounting of PCBs while respecting the fundamental principles for an antistatic workplace. Our facility has the capability to meet your exact requirements for large or small, high density multilayer printed circuit boards or miniature hand-soldered assemblies. Our wave soldering system is completely equipped with every feature and subsystem necessary to achieve the most exacting requirements of multi-layer fine line printed circuit board soldering.
Our extensive experience enables us to routinely solder dense circuits, difficult line geometrics, large lands and odd-shaped printed circuit boards without icicles, bridges, or solder build-up. All variables, such as pre-bake duration and temperature, flux application, density of pre-heat, solder temperature, height of wave, entry angle, and conveyer speed are precisely programmed and controlled to repeatedly obtain a maximum degree of solder quality.
We are able to solder the products using both leaded and unleaded technologies.
The mounted printed circuit boards are soldered at soldering waves, allowing both leaded and unleaded soldering technologies.
According to the customer’s technical specifications, we choose from a surface wave soldering, or selective wave soldering so that the soldering process is reliable, efficient and environment-friendly. An integral part of this process technology is a nitrogen generator ensuring a formation of a nitrogen atmosphere when soldering, thus increasing the quality of a soldered circuit.
We utilize POWERFLOW N2 - Full-Tunnel Wave Soldering System . The Ersa POWERFLOW N2 is a full-tunnel nitrogen wave soldering system developed specifically to master the challenges of lead-free production. With its intelligent controls, the motor-driven fluxer is able to selectively flux specific portions of the printed circuit board. The modular, individually configurable preheat concept ensures a high rate of heat transfer. A multitude of wave formers guarantee excellent solder result regardless of the application. The robust tunnel design and the stable, welded frame underline the durability and the ease of access to the system for service.
The VERSAFLOW 3/45is the selective soldering machine with dual track transport. Depending on the application and on the throughput requirements called for, additional flux, preheat and solder modules can be integrated into the system. In the maximum configuration level of the VERSAFLOW, the system can therefore operate with up to three solder modules, and each of these modules can again be configured with two mini-wave solder baths. In total, up to 6 mini-wave solder bath can be installed in a system, and each solder module can be preceded by a preheat unit.
For PB Soldering solution we utilize Soldering Wave KIRSTEN JET .The soldering wave KIRSTEN is using the system of the hollow wave. The patented electromagnetic pump works without any moving units inside. The fluid solder is accelerating by the electromagnetic area. The wave does not need the nitrogen atmosphere.
As a primary testing technique, AOI applies to fast and accurate
inspection of errors occurring in Assembly Process so that high quality
of PCB assemblies can be ensured with no defects.
Depending on visual methods, AOI test can be applied to detect a lot of surface defects including scratches, nodules, stains, opens, shorts, insufficient or excessive solder, incorrect components, missing components, incorrect polarity of components etc.
Multiple inspection objects
AOI test works perfectly for both bare PCBs and PCBAs. For PCB inspection, defects are checked such as shorts, opens and insufficient solder. For PCBA inspection, issues are inspected including component soldering, polarity and values.
Automated Optical Inspection can be arranged in any stage of manufacturing line in accordance customers' needs. The flexibility attribute of AOI test leads to reduction of cost since it is an in-process test and as soon as issues are discovered, manufacturing or assembly parameters can be instantly modified so that later products will be correctly produced. As a result, more products won't be rejected during functional test or final inspection.
Low cost, Accuracy and Reliability
For AOI we utilize equipment MEK FDAz520.
Optical inspection of correctly applied solder paste or glue in places for placement of SMD components with hidden ball terminals is performed on a Lynx Evo dynoscopic non-ocular stereomicroscope.
Optical inspection of soldered SMD components without terminals or components with hidden ball terminals is performed on X-ray Phoenix microme | x neo.
All assembled and inspected PCBs are washed of flux residues and other contaminants in a single-chamber spray washer.
All PCB Assemblies undergo Aqueous Cleaning at several critical points during the SMT process, especially after any soldering is completed on the board itself. Soldered and inspected PCBs are cleaned of flux residues and other contaminants in a single-chamber spray washer – we utilize Super SWASH IIR+. There are four phases to the cleaning process; boards are immersed in 25% liquid Vigon A201. In second cycle they are rinsed with fresh water. Third cycle contains rinsing in DI water and then they are thoroughly dried.
During the washing process, we use modern technology and put emphasis on environmental protection.
We provide an automated conformal coating application, hand assembling and entire box builds assembly services.
1. AUTOMATED CONFORMAL COATING APPLICATION
We provide a mechanical application of a protective layer of varnish on a fully automated line for electronic assemblies designed for operation in harsh environments.
The protective layer of varnish is applied selectively to precisely specified areas in a defined thickness.
TOROLA electronic utilizes Nordson ASYMTEK The Century C-740/C-741 Series Dispensing Systems providing consistent, uniform dispensing of a variety of conformal coating materials. The system virtually eliminates the requirement for labor-intensive board masking, providing accurately controlled patterns, film builds, and production flexibility in an automated process. Film thickness is achieved in a single pass with little or no masking and with virtually no overspray. The C-740 system incorporates downdraft ventilation for optimized vapor removal. Stainless steel surfaces provide for easy cleaning and maintenance.
The next step in the production chain is manually assembling the printed circuit boards, hand mounting the through-hole components, soldering them and installing mechanical parts.
2. HAND ASSEMBLY
Our highly skilled staff has the manual production capabilities to fulfill your assembly requirements. We specialize in both SMT and Through Hole Hand Assembly and we are able to manufacture small lots, prototypes or mixed technology PCB Assemblies. Our staff has the experience and reliability required to assemble and hand solder Printed Circuit Boards.
The entire assembly service produced by our company all under one roof is not only cost effective but allows for a more efficient assembly process leading to a higher quality product.
Our skilled technicians have the experience necessary to assemble customer’s finished products complying with highest standards of quality. We provide full service as an electronic manufacturer our capabilities including Product Box Building and Testing Services. Our assembly technicians and engineering staff use customer’s documentation of requirements to complete the product on time and on budget.
Our services include packaging, labeling and barcode printing so our customer receives a completely finished product ready for shipment.
Box Build Assembly Capabilities:
Compatible with guidelines of ISO9001:2008 and UL certificates, we offer turnkey and custom box build assembly products and services, including:
All products must go through their final inspection and operational
control where the initiation of product starts. Firmware is uploaded,
set up and tested by our workers.
Performed tests and their results, including testing protocols, are stored in our Information System to keep the traceability running until last steps of the product manufacturing process.
Quality is the core of an electronics manufacturing company so quality control has been covered during all stages of electronics manufacturing process. Quality checks during completion of each phase has to go over rigorous inspections and once defects are observed, rework or modification will be immediately implemented. For after-process quality control, it depends on advanced inspection equipment, such as Optical inspection so that hidden defects can be exposed prior to packaging and delivery.
Our Quality Assurance Technicians have the experience necessary to maximize inspection throughout the SMT Assembly Process. After each major step in the Assembly Process each PCB is inspected thoroughly.
Manufacturing is not complete until all products have been fully tested according to exact specifications. Our team is also able to produce a unique testing procedure if one has not been created and conduct all testing services required.
In TOROLA we have number of test & inspection tools available to ensure delivery of working assemblies to our customers. We work with and on behalf of our customers to develop the perfect testing procedures for their product. The choice of tools depends on the type of assembly and test access points that are designed into the product. Test tools cover a wide range of test options. From optical testing, 3D paste inspection (SPI) and automatic optical inspection (AOI), through functional checks and in-circuit tests to customer-specific optical inspections and stress tests. A high spectrum of tests is required to guarantee that customers are supplied with high-quality, functional products.
We are able to perform such testing with the help of our individual test stations or with our fully automated systems according to the requirements, needs and production volumes specified by our customers.
All initiated and checked products are carefully packed according to
the standards and customer’s requirements and stored in our warehouse.
They wait to be dispatched to our customer or any recipient defined by our customer. Our manufactured products went through the whole box-build assembly process which covers a wide range of additional procedures as simple as putting electronic systems into simple enclosures with interfaces or displays or as complicated as system integrations containing thousands of individual components or sub assemblies. In one word, products after box-build assembly can be directly sent for sale.
We work to understand the requirements of each customer to be able to accommodate any or all of the following order fulfillment/logistics services:
All PCB Assemblies are placed in anti-static packaging before delivery. All boards are given one last wash and touch up before they are tested, barcoded, serialized and photographed. An Inspection Report is attached to each shipment of finished Electronic Assemblies or Box Build Assemblies.
Procurement Department officers are ready to respond to all customer
requirements. The customer feedback is very important for us and is
carefully monitored to improve our services.
Turnkey / Consignment
TOROLA electronic offers the option of manufacturing to build on a consignment or turnkey basis. Both turnkey and consignment assemblies go through many quality check points, however, managing of the entire project from A to Z is our main goal. Our twenty plus years of experience in the industry, along with established suppliers chain allow us to manage the entire process of an assembly until it is complete.
TURNKEY CONTRACT MANUFACTURING
In this model, TOROLA electronic as the outsourced manufacturing partner, has complete control of all production processes - material acquisition, component and product assembly, product testing, up to sales services and warranties. Our company can also provide product design, engineering and other manufacturing design services.
This kind of production model creates an opportunity for our customer to concentrate on their core competencies i.e. customer sales and marketing, and meanwhile we handle the entire manufacturing processes with cutting-edge, modern technologies and capital under the highest quality standards.
CONSIGNMENT CONTRACT MANUFACTURING
Under the consignment model, components supplied by customer are used for manufacturing process. We produce under this model in some cases – such as when a product relies on a highly specialized component that may be supplied specifically from our customer or in cases where a company’s intellectual property is contained in a component or a board.