Cogent Bolster Product Traceability
Joseph Booth • 7 June 2022
Investment in new Laser Marker and BGA Inspection System
“For a medical device manufacturer such as Cogent Technology, traceability of sub-assemblies is vitally important to both the client and the internal Cogent QMS processes.”
Paul Harrison-Rowe, Cogent Technology Engineering Manager.
Background
Established in 1985, Suffolk-based Cogent Technology manufactures cutting-edge medical devices and instrumentation for industry.
A trusted global leader in MedTech, GreenTech, and key sectors like telecoms, diagnostics, security, industrial, instrumentation and control; Cogent Technology occupy a pioneering 80,000 sq. ft. facility with two Class 7 cleanrooms and a 7,000 sq. ft. biological room.
With one of the largest smart factories in Europe, manufacturing for international distribution, Cogent Technology ensures all devices are produced to the highest quality standards and continually enhance their capital equipment investment to guarantee production runs effectively.
The Challenge
As technology advances, printed circuit boards (PCBS) are becoming smaller and more complex to manufacture. Therefore, it is important to have equipment and machinery to handle the shrinking size and density challenges.
With business continuing to grow, Cogent Technology was looking for a solution for the traceability of miniaturized PCBs.
“For a medical device manufacturer such as Cogent Technology, traceability of sub-assemblies is vitally important to both the Client and the internal Cogent QMS processes,” said Paul Harrison-Rowe, Cogent Technology Engineering Manager.
“At the moment, serial number labels are printed and fitted by hand. This was suitable for a low volume batch build process; however, this is now hindered by an ever-increasing demand for volume products, and an ever-decreasing size of printed circuit board and associated available space for labels.”
The Solution
Cogent Technology contacted Altus to discuss possible solutions that would address traceability. Following consultation, it was advised that the YJ Link YLM Laser Marker would meet the challenge.
As the production of highly advanced electronic assemblies increases, the importance of traceability has never been more important. High-tech manufacturers like Cogent Technology are looking for ways to implement processes to improve manufacture which can also integrate seamlessly into a ‘lights-out’ production plan. Aligning with these processes is the YLM Series Laser Marking solution from YJ Link.
Paul said: “In some circumstances, PCBs are either too small, or their specific operational requirements prohibit the use of serial labels. This meant that Cogent needed to find alternative solutions to:
- Double-sided PCBs require the same serial label to be applied on both sides of the PCB to cater for manufacturing equipment constraints.
- Position of the serial number on the PCB, as later full product assembly may require the serial number to be in an exposed readable position so that it can easily be scanned. This is not always possible with a client’s design, as due to the size of a serial number label, it may have to be placed in a specific location.
- Being able to apply serial numbers to very small PCBs.
- Being able to apply serial numbers to PCBs whose operational constraints would not allow a sticky label.
- Reducing the material and labour cost of applying labels, especially considering double side PCBs with 50 or 100 up panels requiring the same serial number on both sides.
“The solution to all of these problems was to invest in a Laser Marking machine that could internally flip over the PCBs and mark the same serial number to both sides, as well as speeding up the application time and reducing cost. Also, since the Laser Marker effectively reduces the size of the serial number real estate, a serial number could now be applied on PCBs where previously it was not possible.”
Meeting the Challenge
The YLM range addressed all of the challenges that Cogent Technology was facing. As one of the most affordable and technologically advanced laser markers available in the marketplace today, it is easy to operate and efficient with fast cycle times to ensure manufacturers meet high production targets with ease.
Integrating a top of the range Panasonic laser solution as standard, fiducial recognition, and an internal flipper, the YLM laser marker helps to achieve a 20% cost saving. There is also a keymark camera helping to prevent the wrong PCB from coming in and hold-down clamping to ensure the correct position is held to maintain marking distance and stop mis-alignment.
Once installed at Cogent Technology it will offer capabilities making it an ideal investment.
“The Laser Marker will allow some other new features to be introduced, such as marking the work order number onto the waste material of the PCB panel or having the ability to be able to mark logos, dates etc. as required,” said Paul .
Investing in Inspection
Cogent Technology made further capital equipment investments with the selection of an Optilia BGA Inspection System. With parts no longer available for their existing machine, the Optilia platform had the modular features that would fit in with the company’s demanding requirements.
Optilia Instruments’ high definition optical BGA inspection systems with its larger Field-of-View can see beneath low stand-off BGAs. It makes hidden balls and rows more visible to find micro-cracks, cold solder joints, whisker, scaling, excess flux and other soldering issues that high-priced X-ray systems cannot detect. In addition, the system features small optical probes and 5.0 megapixel digital image cameras to produce high-resolution pictures of the extremely low-clearance areas beneath BGAs, μBGAs, CSP and FlipChip packages.
Top-view attachable varifocal lenses with built-in LED lighting provide maximum inspection capability and offer flexibility in magnification, probe tip size and in lighting adjustment.
The Future
Joe Booth, Altus CEO said: “ Cogent has been a joy to work with on this project and it is brilliant news that they chose to partner with Altus Group Ltd and in doing so, have bolstered their product traceability and automation significantly. Cogent is a renowned player in medical device manufacturing sector where ensuring product quality is paramount and I am pleased that we can play our part with the YLM Laser marking series for YJ Link and the BGA inspection system from Optilia, both stand out processes from our portfolio. Optilia is the BGA inspection process's originator, and YJ Link is a market leader with its latest YLM laser marking capabilities. I hope this is a start of a long and fruitful partnership and look forward to seeing the units being implemented. ”
Altus Group Partners with Optimum to Bring Smart Klaus Digital Assembly Technology to UK and Ireland
Altus Group, a leading supplier of capital equipment and service support for the electronics manufacturing sector in the UK and Ireland, has partnered with Optimum datamanagement solutions GmbH to introduce the Smart Klaus digital worker assistance system to companies across the region. The partnership comes as electronics manufacturers increasingly look to automate and digitise manual assembly processes in response to ongoing skilled labour shortages and growing demands for traceability and process control. While SMT production has benefited from significant automation investment over recent years, through-hole (THT) and final assembly operations have traditionally remained heavily dependent on manual processes. Joe Booth, Chief Executive Officer at Altus Group, said: "I have been looking for an opportunity to add a top-quality solution to our THT equipment portfolio and I think Smart Klaus is an excellent addition. It is intuitive to use and program, engineered and manufactured in Germany to a very high standard, with a range of well-thought-out options developed through more than 1,500 installations across Europe. "We have all seen simple laser-guided systems, but Smart Klaus goes much further. By displaying instructions directly in front of the operator, incorporating Pick-by-Light functionality and checking each work step in real time through camera-based optical inspection, it reduces the skill level required while helping ensure only the right quality product leaves the production line. "I think this is exactly the type of system our market needs while manufacturers continue to face significant labour and skills challenges. I am excited to hear if our customers are as excited about the technology as I am." Developed by Germany-based Optimum datamanagement solutions GmbH, Smart Klaus is a camera-based worker assistance system designed to digitise manual production processes. The system provides audiovisual step-by-step guidance to operators while one or more integrated cameras continuously monitor the work area and verify that each task has been completed correctly. Using a combination of image processing technology and artificial intelligence, Smart Klaus compares live activity against taught reference images and immediately alerts operators to deviations. Every process step is automatically documented, creating complete digital traceability and providing manufacturers with valuable production data that can be used for process optimisation and training. The modular platform can be configured with features including Pick-by-Light systems, projectors, external digital measuring tools and interfaces to ERP and MES systems. Smart Klaus can be deployed across a range of applications, including incoming goods inspection, manual assembly, THT assembly and final inspection processes. Smart Klaus will make its UK debut at the Altus Group Factory of the Future event in September 2026 and will subsequently be available for demonstrations at the company's headquarters in Redditch.
Altus Group, a leading distributor of electronics manufacturing equipment in the UK and Ireland, has announced a major expansion of its Redditch headquarters following the acquisition of an adjoining facility that will significantly increase its demonstration, training and customer collaboration space. The expansion adds approximately 363 m² (3,900 ft²) of additional space and includes the creation of a new customer experience centre, developed in collaboration with its technology partners. The investment will enable Altus to install a complete inline manufacturing solution at the heart of its facility, allowing customers to see first-hand how a full production environment can be configured across SMT assembly, THT assembly, backend production and component management. The investment follows a period of sustained growth for Altus, with the company increasing its market share and becoming an established long-term partner for electronics manufacturers making new investments. The additional facility will increase demonstration capacity and create dedicated areas for customer training, applications support and collaboration, enabling Altus to further enhance the services it provides across the UK and Ireland. A key part of this development has been the expansion of Altus' portfolio, which now enables the company to offer a complete turnkey solution for an entire manufacturing facility where required. This broader capability allows Altus to support customers with a more complete view of the production environment, rather than focusing solely on individual machines within it. Joe Booth, Chief Executive Officer at Altus Group, said: "The investment into this additional facility represents another important milestone for Altus and provides us with the space to fully demonstrate our capabilities as a single-source manufacturing partner. "The new customer experience centre will allow our prospects and partners to see how an entire production environment can be configured and optimised as one connected process, rather than viewing individual pieces of equipment in isolation. "It will provide a collaborative environment where customers can evaluate technologies, undertake training, discuss manufacturing challenges and gain a better understanding of how a complete turnkey solution can be tailored to their requirements. Our aim is to create a gold standard facility that reflects how modern electronics manufacturing operates." The expanded customer experience centre will be located alongside Altus' existing purpose-built headquarters in Redditch, which opened in 2019, and is expected to open in September 2026. For further information, contact Altus Group at www.altusgroup.co.uk .
Altus Group, a supplier of capital equipment and service support for the electronics manufacturing sector across the UK and Ireland, has invested further in its Irish operation with the appointment of two new field service engineers. The company has appointed Brian Andrews and James Langham following a period of significant growth in Ireland, during which Altus has secured several new customer accounts and increased activity across the region. The appointments will further strengthen local service and technical support capabilities as demand for the company's solutions continues to grow. Mike Todd, Operations Director at Altus Group, said: "Following the tragic passing of our colleague and field service engineer, Michal Ostrykiewicz, earlier this year, it was important to us that we took the right action because of how highly regarded he was by both customers and colleagues. Michal played a significant role in establishing our reputation for technical support in Ireland and helped create the strong foundations we continue to build upon today. "We wanted to honour that legacy by continuing to invest in our Irish operation and maintain the momentum he helped create. As our customer base in Ireland continues to grow, maintaining the high levels of aftersales support our customers expect remains a priority. "Brian and James both bring valuable industry experience and will play an important role in supporting our customers as we continue our ambition of becoming the go-to partner for electronics manufacturers across Ireland." Brian joins Altus with extensive experience gained across both equipment suppliers and electronics manufacturing operations. Having previously held positions with Mycronic covering the UK and Ireland before moving into an Operations Manager role with Smart Electronics, he brings experience from both supplier and manufacturer perspectives. Based in the Shannon region, he will support customers throughout Ireland with equipment installation, service and technical support. James joins Altus from Moog, where he most recently worked as a Maintenance Engineer. Based in Cork, he brings valuable manufacturing experience and a strong understanding of equipment maintenance, uptime and production support. His background provides first-hand insight into the challenges faced by electronics manufacturers and the importance of responsive technical support. Both engineers will undergo extensive supplier training and mentoring programmes over the coming months, working closely with customers while continuing to develop their expertise across Altus' portfolio of manufacturing technologies. The appointments represent the latest stage in Altus' investment in Ireland, following the establishment of its Irish entity, investment in local facilities and continued expansion of its team. The company continues to invest in its people, systems and infrastructure to support the evolving needs of electronics manufacturers across the region.
Strengthening reflow solutions for the UK & Ireland
Altus Group, a leading distributor of electronics assembly equipment in the UK and Ireland, has supported Esprit Electronics, an electronics manufacturing services provider, in selecting new best-in-class inspection technology from Koh Young following an evaluation process. Operating across two production facilities with five SMT lines, Esprit Electronics manufactures complex PCB assemblies for customers in high-reliability sectors including medical, military and industrial electronics. As part of a review of its inspection strategy, Esprit’s engineering team evaluated several inspection technologies available on the market. The process included a comparison of camera-based, laser-based and Moiré fringe-based inspection systems, with demonstrations and trials carried out using the same representative PCB assembly. Rob Pembroke-Burn, Production Engineer at Esprit Electronics, said: “It was really great to get a chance to spearhead the technical review aspect of this investment, having lived and managed the challenges of our existing inspection processes. The breadth of and quality of technology and the advancements are eye opening. We knew that whichever unit we selected was going to be a step up for the company, but our job was to identify the best technology among the leading platforms.” Following demonstrations conducted with Altus Group, the Koh Young Zenith 2 AOI system demonstrated clear advantages for Esprit’s complex PCB assemblies. The platform uses True 3D measurement technology based on Moiré interferometry, capturing precise height and volume measurements across the PCB surface rather than relying solely on two-dimensional image analysis. This approach enables accurate inspection of solder joints and components across complex PCB layouts while reducing the assumptions typically associated with conventional AOI systems. Following further technical discussions with Altus and a subsequent review, Esprit confirmed its decision to invest in two Zenith 2 systems equipped with eight-megapixel imaging, Offline Programming (OLP) capability and the KSMART Pro software platform. The Koh Young Zenith 2 platform combines high-resolution optics, advanced vision algorithms and multi-projection Moiré interferometry to generate detailed 3D inspection data across the entire PCB surface. The system also integrates Koh Young’s KSMART software environment, which enables manufacturers to analyse inspection data and apply statistical process control tools to support process monitoring and improvement. Allan Hawkins, Production Engineer at Esprit Electronics, said: “What a good result! The team and I are really happy with the investment and the step up in our inspection capacity. We are excited about the impact the technology will have on our internal efficiencies and processes, but ultimately the quality we can ensure our customers receive.” Altus Group worked closely with the Esprit Electronics throughout the evaluation process, supporting the assessment of inspection technologies and demonstrating how measurement-based 3D inspection can provide greater process visibility for complex electronics manufacturing.
Altus Group, a leading distributor of capital equipment for electronics manufacturing in the UK and Ireland, has highlighted the customer benefits of YJ Link’s continued global growth, as the manufacturer of SMT board handling equipment, laser marking machines and routers expands its manufacturing capacity and strengthens its international install base. YJ Link, a long-term Altus partner, has continued to scale its global operations, with a new production facility in Bengaluru, India, forming part of its wider manufacturing expansion. According to YJ Link, the facility is intended to strengthen global market responsiveness, improve response speed for customers and support overall supply chain stability. For customers, this wider growth is expected to support faster lead times, improved availability and greater project flexibility. Altus also expects YJ Link’s increasing scale and larger global install base to support more competitive pricing, a broader product portfolio and continued product development for demanding electronics manufacturing environments. Joe Booth, CEO at Altus Group, said: “YJ Link’s continued growth is very positive for customers in the UK and Ireland. As manufacturing capacity increases, we are better placed to support local projects with shorter lead times, while also benefiting from the efficiencies that come with greater economies of scale. “This is particularly important as more electronics manufacturers look to automate production, improve line efficiency and invest in flexible equipment that can support both current and future requirements.” The new India facility will form part of YJ Link’s four-pillar global production system, alongside existing manufacturing operations in Korea, Vietnam and Mexico. Once completed, it is expected to add up to 500 units per month, increasing YJ Link’s total global monthly production capacity to 1,500 units. Altus will continue to support manufacturers across the UK and Ireland with local access to YJ Link’s equipment, backed by technical advice, installation support and after-sales service from its experienced engineering team.
Altus Group, a leading distributor of capital equipment in the UK and Ireland, has supported Prism Electronics Manufacturing in its investment in advanced X-ray component counting and smart storage technology to enhance traceability and efficiency at its Cambridgeshire facility. Prism Electronics Manufacturing, a leading UK contract electronics manufacturer, has invested in strengthening its component management capability to support continued operational efficiency and competitiveness. Building on existing Altus-supported systems at site, Prism selected the Scienscope AXC-800 III X-ray Component Counter together with two modular Scienscope Smart Storage Racks. The Scienscope AXC-800 III delivers high-speed, high-accuracy counting, scanning four 7-inch reels in under 10 seconds with very high repeatability and integrated barcode verification. The Smart Storage Racks provide automated reel tracking, LED-guided multi-kitting and full traceability, with integration into ERP and MES systems enabling real-time inventory updates and improved stock control. Joe Booth, CEO, Altus Group, said: “As we supply a complete range of component management solutions, including storage racks and scanning tables, we are not limited to a single product. This gives us a strong understanding of system integration, which is critical to the success of any project. Scienscope has established a leading position in the UK and Ireland for component management, not only in X-ray counting but increasingly in smart storage and scanning solutions, giving customers like Prism confidence in both the technology and the long-term support behind it.” Cheyenne Rowe, Managing Director at Prism, said: “This is one of a number of strategic investments we are making to modernise and improve our offering to customers. It is great to see the systems on site, and we are really happy about modernising our approach to component management and traceability. This investment will significantly increase our level of component traceability and automation of information capture streamlining the way we manage stock.” The system was installed and operational within weeks of purchase, with full integration into Prism’s existing production infrastructure, supported by Altus’ local technical expertise including for ongoing customer support.
Altus Group, a distributor and service provider of capital equipment for the electronics manufacturing industry, has supported the development of a multi-system 3D AOI inspection strategy at Custom Interconnect Ltd (CIL), which is described as the UK’s largest outsourced semiconductor packaging and test provider. The collaboration reflects a long-term partnership aligned with CIL’s increasingly complex manufacturing requirements. Since 2019, Altus has supplied Seven Koh Young 3D AOI systems to CIL, supporting the staged expansion of inspection capability. The partnership began with standalone Koh Young Zenith 2 systems for high-mix, low-volume production. This progressed to inline deployment as production requirements evolved and CIL’s revenue grew from £15 million in 2021 to £37 million in 2024. Supplied and supported by Altus, Koh Young Zenith Alpha HS+ systems have since been introduced across higher-volume SMT lines, with inspection now deployed across multiple lines and facilities to support a mix of high-mix and higher-throughput manufacturing environments. Joe Booth, chief executive officer at Altus Group, said: “This has been a relationship that has developed over time. As CIL’s manufacturing requirements have changed, our focus has been on supporting inspection capability that fits how their production operates in practice, working closely with the team both before and after installation to ensure they continue to get value from their systems and have the right support in place as requirements evolve.” As inspection requirements evolved, the relationship moved beyond individual system installations to include longer-term planning and technical support, with Altus supplying and supporting Koh Young AOI systems while acting as the technical interface between CIL and the manufacturer. Jason Reid, operations manager at Custom Interconnect Ltd, said: “Altus will always help us to look at what’s next and what we can do with our current equipment. What do we need to learn? What do we need to be thinking about? Because there are things that we’ll look at that we’ve probably not even tried yet, and that’s what they’re there for. They’re there to support us to do that.” The partnership has also benefited from continuity of technical expertise. In 2023, Paul Freeman joined CIL as head of PCBA engineering following his previous role as senior applications engineer at Altus, further strengthening the relationship and alignment between inspection technology, process knowledge and production requirements. Altus continues to support CIL with application support, inspection optimisation and longer-term planning as product complexity and customer expectations continue to evolve and CIL’s production capacity continues to grow.
DDJ Expand Territory Coverage Into Benelux
Altus Group, distributor of capital equipment for the electronics manufacturing industry, has supported Ei Electronics, Ireland’s largest manufacturer of home life-safety devices, with the installation of an LPKF CuttingMaster 2240 laser depaneling system to enhance PCB singulation and support growing production volumes. From its integrated manufacturing facility in Shannon, Ei designs and produces smoke, heat and carbon monoxide alarms supplied to markets worldwide. With new product variants progressing through NPI and increasing demand across several lines, the company reviewed opportunities to strengthen its depaneling process as part of wider investments in automation and advanced manufacturing. David Keating, Group COO Ei said: “As part of its ongoing drive toward advanced manufacturing and product excellence, Ei Electronics is transitioning from manual PCB breakout to laser singulation across its production lines. This strategic move is designed to enhance precision, consistency, and product reliability.” Following evaluation, the LPKF CuttingMaster 2240 was selected for its non-contact, high-precision cutting process and clean, stress-free PCB separation. “Laser singulation eliminates these risks by using a non-contact, high-precision cutting process, ensuring cleaner edges, minimal debris and significantly reduced mechanical strain,” said David. Although Ei’s new system is the standard CuttingMaster 2240, the company played a role in LPKF’s early development of the Cx platform concept after placing its first order in 2022. That collaboration helped inform the inline, fixture-free handling approach now widely adopted across the market. The system now acts as the first stage in Ei’s backend assembly and test flow, supporting stable cycle times and consistent throughput as production ramps up across multiple alarm variants. David continued: “The adoption of laser technology supports greater automation and scalability. By integrating laser singulation into its state-of-the-art SMT environment, the company achieves higher yields, improved quality assurance and enhanced throughput.” Gareth Fenton, sales manager at Altus Group, said: “It has been a pleasure to be part of this exciting project. Ei Electronics is an impressive organisation, and it’s a source of great pride to see a semi-automated production line now in operation.” With further systems scheduled for late 2025 and early 2026, the investment marks the next phase in Ei’s long-term manufacturing strategy.
