en.Wedoany.com Reported - Imperial Electronic Assembly, a contract manufacturer based in Connecticut, USA, has reduced cycle time for complex circuit board products from approximately 15 days to 8 to 9 days by introducing Koh Young Technology's online Automated Optical Inspection (AOI) and Solder Paste Inspection (SPI) systems, while improving quality ratings to 99.9% or 99.8%. Since its founding in 1989, the company has grown from a team of 10 to an enterprise with 120 employees and a 45,000-square-foot facility.
Imperial previously relied on batch AOI systems in its quality control process, which created production bottlenecks and delayed problem feedback. Engineering Manager Mark Bohacs stated that the batch system meant products had to be processed in batches, preventing real-time quality feedback. Operations Manager Mike Conte added that there was a waiting period after products passed through Surface Mount Technology (SMT) before AOI, which could lead to rework of defective batches. As technology evolved, the company recognized the need to introduce SPI to address challenges with finer pitches and Ball Grid Array (BGA) packages.
Imperial evaluated approximately three different AOI and SPI suppliers and ultimately chose to partner with Koh Young. Mark Bohacs noted that Koh Young excelled in printer integration, upstream and downstream integration capabilities, and true 3D imaging quality, with its Casemark product providing easily accessible information. Offline programming and repair station features were also considered significant advantages. Operations Manager Mike Conte emphasized that the collaborative team between Koh Young and Imperial's production line supplier Panasonic was highly beneficial. Founder and CEO Tony Conte confirmed that Panasonic's recommendation played a key role in the decision.
As a contract manufacturer producing multiple products for various clients, Imperial required exceptional flexibility. Mark Bohacs explained that the company chose the Zenith UHS AOI because it offers true vision and board control capabilities, can handle a wide range of potential product types, and provides flexibility in different configurations.
The installation and training process exceeded expectations. Mark reported that Koh Young's team was thorough and professional, explaining multiple approaches to achieve goals during installation and training, and was highly responsive. Remote support capabilities were also considered valuable, allowing quick connection and interactive problem-solving. Imperial first installed AOI systems on two existing production lines, preparing for a fully integrated third line.
The user-friendly interface of the Koh Young system enables non-engineering personnel to operate effectively. Mark noted that having intuitive and easy-to-navigate data is crucial, allowing operators to immediately see trends and understand system feedback. The comprehensive data integrated through the KSMART software has transformed Imperial into a more data-driven organization. Mike stated that the volume of data is immense, enabling engineers to continuously understand what the system is looking for and how to maximize uptime. Building a comprehensive component library accelerated new product introductions, with improvements in programming time and initial setup time. The three production lines are connected via KSMART, with all feedback continuously updated, allowing the team to communicate and deploy changes across all three lines.
Founder and CEO Tony Conte emphasized that data analysis is a vital part of the company's progress, with engineering staff dedicated to data collection, analysis, and process adjustments. The company has added a significant number of engineering personnel and developed 3D fixtures for manual assembly, making the process more quality-driven and precise.
Koh Young's 3D imaging provides detailed information, enabling Imperial to quickly identify and resolve issues. Mark stated that the company has been highly successful in root cause analysis, with the system helping to immediately see drifts and changes in equipment output, allowing for targeted adjustments. Implementation results show that cycle time has nearly halved, quality ratings have reached 99.9% or 99.8%, and operational efficiency has significantly improved. Tony Conte added that product quality has improved, rework has decreased, errors have been eliminated, and processes have accelerated.
By adding Koh Young's SPI and AOI systems, all inspections are now performed online, providing immediate feedback, reducing process errors, and improving first-pass yield. Mark views Koh Young as a technology leader in the inspection market, considering its technology to be true 3D, with images, quality, and data that are very easy to use. Tony Conte emphasized that having equipment capable of identifying problems and placement accuracy is critical to success, and as components become smaller, suppliers need to invest in R&D.
Imperial values its ongoing partnership and support with Koh Young. Mike summarized that working with the Koh Young team has improved the overall factory process and shortened lead times, with technical support being highly responsive. The investment in Koh Young technology is part of Imperial's broader growth strategy. Tony Conte stated that the company plans to expand its customer base, potentially with a larger facility and additional equipment. Advanced inspection capabilities have become a competitive advantage, demonstrating automated processes and product flow management capabilities during customer visits.
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