Case Study: EMS Manufacturer (6x Auto Soldering Machines)

How a Penang-Based EMS Manufacturer Automated 6 Antenna PCB Models with Modular 4-Axis Soldering 

Customer Profile 

• Industry: Electronics Manufacturing Services (EMS) 
  
• Location: Penang, Malaysia 
  
• End Product: RF Antenna Modules 
  
• Production Type: Medium-volume, multi-model PCB assembly 
  

The manufacturer produces antenna PCBs for telecommunications and industrial applications, where solder joint consistency directly impacts signal performance and reliability. 

The Challenge 

The customer was managing 6 different PCB models, each requiring manual soldering processes.

Challenges included: 

• Operator dependency across multiple models 
  
• Inconsistent solder quality between shifts 
  
• Difficulty scaling output without increasing headcount 
  
• Risk of yield variation affecting RF performance 
  
• Production complexity due to model segregation 
  

Because each PCB model had different soldering points and process parameters, scaling manually required more skilled operators — increasing cost and variability. 

Why Automation Was Considered 

The customer needed to: 

• Segregate production by PCB model 
  
• Improve process stability 
  
• Reduce reliance on manual soldering operators 
  
• Prepare for higher production demand 
  

They required a solution that allowed: 

• Dedicated setup per model 
  
• Repeatable, programmable solder paths 
  
• Compact deployment without major line redesign 
  

The Solution 

Tokimeku implemented: 

6 units of the Toki 4-Axis Auto Soldering Machine (400mm) 

Each unit was configured and dedicated to one PCB model. 

This enabled: 

• Model-based segregation 
  
• Stable programmed solder parameters 
  
• Independent scaling per product line 
  
• Reduced operator variability 
  

Instead of redesigning the entire line, the customer deployed modular automation cells that fit within existing production areas. 

Why Modular Machine Deployment Was Strategic 

Rather than using one shared automation cell and switching programs between models, the customer chose 6 units to: 

• Eliminate changeover downtime 
  
• Maintain process stability per model 
  
• Improve production planning 
  
• Avoid cross-model contamination risks 
  

This structure simplified workflow and improved operational discipline. 

Expected Benefits 

The key targeted outcomes include: 

• Reduced operator dependency 
  
• Improved solder yield consistency 
  
• More stable RF performance across batches 
  
• Predictable and repeatable solder quality 
  
• Scalable output without proportional labour increase 
  

In antenna manufacturing, even minor solder inconsistencies can impact signal performance. Automated precision helps reduce that risk. 

Strategic Impact 

By deploying 6 dedicated automation cells, the manufacturer: 

• Transitioned from manual variability to programmed repeatability 
  
• Built scalable infrastructure for multi-model production 
  
• Strengthened production control for quality-sensitive antenna assemblies 
  

The modular approach allowed them to automate confidently without committing to a full custom line. 

Request a Process Evaluation

Manufacturing multiple PCB models and struggling with manual soldering variability? Discover how modular automation can stabilise yield and scale your production.

Tokimeku can evaluate consolidation opportunities through integrated automation.  Speak to our automation specialists to assess feasibility.