Electronics manufacturing is becoming increasingly complex, requiring short development cycles and diverse product variants while simultaneously meeting the highest standards of quality and efficiency. To meet these challenges, we at Zollner Elektronik AG have rethought our data processes—and are consistently relying on PCB Investigator.
Zollner is a leading manufacturer of high-quality electronic components, with production facilities at 16 international locations. With years of experience in the industry, the company has earned a reputation for innovation and reliability. Zollner offers a wide range of products and services, including the development of customized solutions for various industries such as automotive, medical, and aerospace. The company uses state-of-the-art technologies and strict quality control procedures to ensure that every product meets the highest standards. In addition, Zollner is committed to sustainability and continuously works to promote environmentally friendly production methods.
Why we introduced PCB Investigator
The traditional method of creating placement programs using file exchange formats was no longer efficient for us. Different systems, manual checks, and media breaks were time-consuming, consumed resources, and were prone to errors. We often had to enter data multiple times and compare it manually, which led to delays. These processes required a lot of manpower and were also prone to errors. In addition, we had to use different software solutions, which further increased complexity. Every time an update or change had to be made, it meant additional effort and the risk of inconsistencies. Although this traditional approach was acceptable in the past, it turned out that it no longer met modern requirements for speed, precision, and efficiency.
It has become clear that a much more robust and automated solution is needed to not only optimize the entire process, but also to streamline it comprehensively. Such a solution would not only significantly increase efficiency, but also minimize the potential for errors and ensure consistent quality. In the course of implementing this advanced technology, it would be possible to harmonize systematic processes while using resources more efficiently, which could lead to significant competitive advantages in the long term.
With PCB Investigator, we were able to establish a comprehensive, automated solution that offers everything from layout analysis to machine connection from a single source. We were particularly impressed by the ability to transfer assembly data directly to our machines via interfaces such as ASMPT OIB or Essemtec—without any manual intermediate steps.
This is how the process works today
The layout is automatically checked to determine whether the components correspond to our internal libraries. PCB Investigator suggests suitable geometries or detects missing parts. It also checks whether a component is already stored on a machine and uses it via copy if necessary. This process ensures seamless integration of components and reduces human error by using advanced algorithms to identify problems.
The benefits are then created in coordination with manufacturing, testing, and assembly. Our knowledge of production requirements is automatically incorporated. Various parameters are taken into account, such as the thermal requirements, mechanical load capacity, and electrical properties of the components. The result is a well-thought-out design that optimizes both quality and efficiency. This careful planning allows us to maximize product life and keep production costs to a minimum.
One tool for all areas
A major advantage: a single tool for all areas. PCB Investigator combines data preparation, quality management, purchasing, and machine operation in one system. This not only increases efficiency but also improves the flow of information between the various units. The integration of different processes into a single platform facilitates collaboration and prevents errors that could arise from isolated systems.
PCBI 365 enables us to manage and provide data securely and flexibly. This solution offers us a cloud-based infrastructure that allows us to access important information anytime, anywhere. PCBI 365 also ensures the protection of sensitive company data thanks to its robust security mechanisms. Employees can therefore work more efficiently by finding and processing relevant data more quickly, which in turn leads to higher productivity and better results.
Our lessons learned from the project
- Same database for everyone: no more version conflicts, no reworking.
- Faster product launch: machine compatibility check directly during data preparation.
- High degree of automation: consistently high data quality regardless of who is processing it.
- Production reliability: early detection of multiple definitions or gaps.
Conclusion: Higher quality, less effort
PCB Investigator has proven to be an indispensable strategic tool for optimizing our highly complex manufacturing processes. Seamless integration with our advanced placement machines significantly minimizes potential sources of error, resulting in a significant acceleration of product ramp-up and thus increasing our efficiency and quality. It enables in-depth analysis and monitoring of our production lines, enabling us to make continuous improvements and secure our competitiveness in a demanding market.
Investing in end-to-end data processing has paid off for us in every respect—delivering greater security, efficiency, and future-proofing in electronics manufacturing.
About the software provider EasyLogix
EasyLogix has sold over 30,000 CAD/CAM licenses worldwide. Known for its solutions in the field of electronics design and automation, the company serves customers in various industries such as aerospace, automotive, and medical technology. By providing powerful and user-friendly software, EasyLogix has made a significant contribution to optimizing design processes and increasing the efficiency of product development. EasyLogix CAD/CAM licenses are now an integral part of the workflows of many leading companies on a global scale.
As specialists in manufacturing machinery, we have extensive experience in handling data formats and connections to support electronics manufacturing and development. Our team is highly skilled in the implementation and optimization of SMT (Surface Mount Technology) lines and in the handling of complex pick-and-place machines. We offer customized solutions to increase production capacity and ensure maximum precision using state-of-the-art automation techniques. We are also experienced in integrating our tools into various MES (Manufacturing Execution System) systems for real-time monitoring and control of manufacturing processes. Our expertise also extends to the analysis and improvement of process flows using Six Sigma and lean manufacturing methods. With our in-depth technical expertise, we help to continuously increase the efficiency and quality of your electronic products.
Interview with Andreas Koller, Zollner Elektronik AG Global Engineering, and Günther Schindler, Managing Director of EasyLogix.
Mr. Koller, why was Zollner so eager to find a new solution for creating placement programs?
Andreas Koller: We work with a very wide range of products and an international manufacturing network. The manual processing of pick-and-place data was a real bottleneck. Above all, the multitude of formats, libraries, and systems slowed us down. With PCB Investigator, we have taken a decisive step forward—we can now communicate directly with the machine from the layout, without any detours.
Mr. Schindler, what makes PCB Investigator so special?
Günther Schindler: We recognized early on that traditional file formats such as CSV or TXT are no longer up to date. The future lies in direct interface communication, for example via ASMPT OIB or Essemtec API. This automatically synchronizes the machine library, and the user can immediately see: Is the component already available? Does it need to be created from scratch? Or can an existing geometry be reused?
Andreas Koller: That’s worth its weight in gold for us. In the past, it sometimes took us days to check compatibility. Today, we receive live feedback from the machine—while the data is being processed.
What does this process look like in concrete terms?
Andreas Koller: We start with the layout and bill of materials in PCB Investigator. There we check the pad geometries, compare the components with the library, and create the manufacturing layout directly in the tool. The function for detecting multiple definitions and suggesting the optimal geometry is particularly helpful—all before the first run.
Günther Schindler: And thanks to the connection to PCBI 365, this workflow can even be replicated across locations. Data, approvals, and feedback from the line are stored and versioned centrally—ideal for global EMS service providers such as Zollner.
How does this affect quality and production reliability?
Andreas Koller: Enormously. We now have a uniform data source, independent of the operator or location. The processes are standardized and traceable, which is a real benefit for quality assurance. In addition, the start-up times for new products have become significantly shorter.
Günther Schindler: That was exactly our goal. PCB Investigator should not be a black box, but an open system that combines efficiency, transparency, and quality—from CAD data analysis to the machine line.
Your conclusion?
Andreas Koller: PCB Investigator has changed our way of thinking. We now see manufacturing as a networked overall system in which every decision made in processing also has an impact on production, testing, and quality. For us, that was a real game changer.
Günther Schindler: And for us as developers, that’s the best confirmation we could ask for: when software not only works, but also delivers real added value. (sb)
Here is the report from “Elektronik Praxis”: User report
