Saki’s Inspection Systems Adopted by Alps Alpine

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Saki Corporation, an innovator in the field of automated optical and X-ray inspection equipment, is pleased to announce that its 3D Solder Pastes Inspection (SPI) system and Automated Optical Inspection (AOI) system have been implemented at the Kakuda plant of Alps Alpine Co., Ltd. (hereinafter “Alps Alpine”) located in Miyagi Prefecture, Japan.

As a solution partner of the FUJI Smart Factory™ (FSF™), Saki has contributed to the implementation of an advanced, fully automated surface mount line at the Kakuda Plant. This installation supports Alps Alpine’s strategic objective of attaining complete line automation, as well as enhancing operational efficiency and inspection quality across the line through seamless FSF integration.

Background and Objectives

Alps Alpine is a global company that specializes in the manufacture of electronic components and automotive information systems. At its Kakuda plant, the company manufactures communication modules for its Sensor & Communication business segment.

Alps Alpine has prioritized the transition to a fully unmanned SMT production line in response to ongoing labor shortages and production challenges, which included frequent printer-related downtime and limited repeatability and speed in inspection processes. In recognition of these limitations, Alps Alpine decided to overhaul their surface mount line and chose Saki’s SPI and AOI systems due to their seamless M2M compatibility with FSF, unrivaled inspection accuracy and proven reliability in quality assurance.

Saki’s Inspection Solutions Installed at the Alps Alpine Kakuda Plant

1. High-Precision 3D SPI – 3Si Series
High-speed, high-accuracy inspection of critical solder paste parameters, such as area, height, volume, bridging, solder peaks, and BGA coplanarity.

2. High-Resolution 3D AOI for Dense Assemblies – 3Di Series
For complex board designs with ultra-small and tall components, the systems’ high-resolution imaging capabilities deliver accurate and fast visual inspections.

3. M2M Integration with the FUJI Smart Factory™ – Full Line Automation and Labor Savings
- Automated Feedback from SPI to Solder Printer
Misalignment data captured by the SPI is automatically fed back to the printer for real-time correction, thereby improving print quality.

- NG Board Skip Function (Remote Board Skip)
Boards flagged as NG by the SPI are communicated to the pick-and-place and AOI machines to skip unnecessary placement and inspection of defective boards, thereby reducing waste and downstream defects.

- Remote Monitoring via FSF Mobile Conductor
Saki’s systems are compatible with the FSF Mobile Conductor, enabling remote, real-time monitoring and control of line status and alarms. This enhances labor efficiency and productivity.

Benefits and Future Outlook

Mr Hisao Miura, Plant Manager at Alps Alpine’s Kakuda Plant, commented: “After introducing Saki’s SPI and AOI systems to our production line, we’ve seen stable first-pass yields and significantly improved operational uptime. We aim to further reduce false calls to zero by leveraging Saki’s AI solutions and will continue to move forward with building a completely unmanned SMT line. Together with Saki, we are committed to advancing manufacturing technology and further establishing ourselves as industry leaders.”

Mr Ken Katsumi, Saki’s Head of Japan Sales, added: “It’s our great honor to support the production quality of Alps Alpine and, alongside our pick-and-place partners, contribute to greater safety and reliability in society. With seamless M2M integration, Saki’s inspection systems drive labor-efficiency, automation, and excellent quality across the entire SMT line. We remain committed to supporting our customers with advanced total inspection solutions that meet the evolving needs of smart manufacturing.”