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.
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.
Flexibility
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.
3.BOX BUILDS
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 CONTROL
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.
TESTING SERVICES
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.
