Luke Minnis, Manufacturing Product and Process Engineer, Active-PCB, Joe Booth, Chief Executive Office, Altus Group UK and Brent Fischthal, Head of Global Marketing Communications, Koh Young.
Active-PCB Solutions, an Electronics Manufacturing Services (EMS) provider in Reading, UK, continues to raise the bar in inspection performance by expanding its investment in Koh Young 3D Automated Optical Inspection (AOI) technology. With a legacy of delivering high-complexity assemblies for small to medium-batch productions since 1997, Active-PCB has earned a strong reputation for its responsive manufacturing solutions and quality-driven approach.
Specializing in demanding assembly processes—such as flip-chip, package-on-package (PoP), Micro BGAs, QFNs, and ultra-fine pitch components—Active-PCB also offers comprehensive services like repair, rework, and refurbishment. The company backs these services with advanced capabilities, including X-ray validation for BGA and QFN rework, ensuring it consistently meets customer requirements for precision and reliability.
“I have been a Koh Young and Altus partner for many years now, and we are happy to keep building on our partnership and to bring in another 3D AOI. This investment is a clear sign of our ambitions for the future and our desire to implement the best-in-class processes at our facility.”
Luke Minnis, Manufacturing Product and Process Engineer, Active-PCB
Elevating Inspection Capabilities
Recognizing the limitations of 2D inspection in a high-mix, high-reliability environment, Active-PCB set out to strengthen its inspection capabilities with true 3D measurement. The goal: deliver more accurate, repeatable, and traceable inspection results across all product builds.
Two years ago, the company took its first step by implementing the Koh Young Zenith Alpha HS+, a high-speed 3D AOI system enhanced by AI-driven algorithms. The success of that system led to a second investment in the same model, reinforcing their commitment to continuous process improvement and customer satisfaction.
The Power of 3D AOI
The Koh Young Zenith Alpha HS+ is engineered for performance. With a four-projector Digital Light Processing (DLP) architecture, it achieves full 3D metrology with 15-micron resolution and a 25mm measurement range. These capabilities enable the reliable inspection of intricate component structures and densely populated boards with exceptional accuracy.
Beyond hardware, the system’s integration with Koh Young’s KSMART platform provides real-time process visibility and optimization. KSMART delivers actionable insights through measurement-based process analysis and statistical process control, allowing manufacturers like Active-PCB to implement data-driven improvements on the SMT line.
“3D AOI is critical in ensuring that the products we manufacture at our site meet the highest technical standards,” said Luke. “However, the AOI is also about being able to keep improving even our best products, so that we get closer and closer to perfect assembly each time they are run. KSMART and the Statistical Process Control software allow us to create value from the enormous amounts of data that we are capturing and take a pragmatic, data-based approach to incrementally adjust the processes of the SMT line and confirm that the adjustments are positive in real-time.”
Achieving Tangible Results
The addition of the second Zenith Alpha HS+ has already delivered measurable benefits. Most of Active-PCB’s customers now receive products inspected by Koh Young systems, and the expanded capacity ensures they can maintain quality at scale. The transition to 3D AOI has not only boosted confidence in inspection results but also reduced false calls and enhanced traceability throughout production.
Anthony Oh, Technical Applications Manager at Altus Group, added: “It is always nice to get repeat orders from our partners, as it shows they are happy not just with the machine performance, but with the support we provide as well. This ultimately means the machine is generating the expected return on investment they had planned. Active-PCB is a significant player in the UK CEM space, so to have their continued trust and investment is something we are very proud of.”
“The Active-PCB team has always been a joy to work with, and it’s great to see how seamlessly the new unit has been implemented. We look forward to continuing to support them as they leverage the AOI platform to drive further improvements in their manufacturing processes.”
Commitment to Quality and Innovation
Active-PCB’s investment in a second Koh Young 3D AOI system underscores its strategic focus on quality, innovation, and customer satisfaction. By embracing advanced inspection technologies and process control tools, the company is not only strengthening operational efficiency but also reinforcing its leadership in the competitive EMS market.
Koh Young is proud to support Active-PCB in its journey toward smarter manufacturing and zero-defect production.
About Active-PCB Solutions Ltd
At Active-PCB Solutions, we’re more than just a contract electronics manufacturer; we’re your partner. Our comprehensive, one-stop approach covers everything from PCB assembly and prototyping to full-scale electronics manufacturing. We are driven by a commitment to quality, precision, and reliability, ensuring that every product which leaves our factory in Reading, UK, meets the highest standards. From your initial prototype to mass production, a dedicated Account Manager will keep you updated throughout the process, ensuring a seamless, stress-free manufacturing experience. Partner with Active-PCB, so you can focus on growing your business while we handle the rest.
www.active-pcb.com sales@active-pcb.com
