USE CASE
Alps Alpine Co., Ltd.
Improving Inspection Quality and Production-Line Uptime
Overview
Alps Alpine Co., Ltd. is a global manufacturer whose core businesses span electronic components and automotive information systems. At its Kakuda Plant, the company is developing an automated printed circuit board assembly line incorporating advanced inspection systems.
To support this initiative, Alps Alpine introduced SAKI’s 3D-SPI and 3D-AOI systems together with SAKI’s AI solutions. These technologies help the plant automate inspection processes while simultaneously improving inspection quality, stabilizing first-pass yield, and increasing overall equipment uptime.
Why Alps Alpine Chose SAKI
To address the inspection accuracy and throughput limitations of its previous equipment, the Kakuda Plant selected SAKI’s inspection solutions. The goal was not simply to replace individual machines, but to establish a more dependable inspection environment capable of supporting stable, highly automated production.
The installed inspection systems include:
- 3D-SPI (3D solder paste inspection system)
- 3D-AOI (3D automated optical inspection system)
By deploying these systems at key stages of the assembly process, Alps Alpine can monitor print quality and component placement more consistently, helping ensure a stable supply of high-quality products across the entire production flow.
Comment from Mr. Shima, Alps Alpine Co., Ltd.
“The inspection accuracy is excellent, our first-pass yield remains stable, and we are able to maintain a high equipment uptime. One of the most noticeable improvements has been the reduction in false calls. Compared with our previous inspection environment, the line now operates more smoothly and consistently. In quantitative terms, defective products escaping to downstream processes previously measured approximately 5 ppm. We have now reduced that level to below 1 ppm.”
Results and Benefits
By combining SAKI’s inspection platforms with AI-enabled capabilities, Alps Alpine has achieved—and expects to further build on—the following benefits.
Stable Inspection Quality
High-accuracy inspection supports demanding assemblies, including high-density printed circuit boards and mixed boards populated with both ultra-small and tall components. This capability helps maintain a stable first-pass yield and high equipment uptime.
Higher Uptime Through Fewer False Calls
Defect escapes to downstream processes have improved from approximately 5 ppm to below 1 ppm. Alps Alpine also expects SAKI’s AI solutions to further reduce false calls, minimizing unnecessary verification and supporting smoother, more efficient line operation.
Automated Line Enabled by Equipment Integration
FUJI’s FSF platform is linked with SAKI’s SPI and AOI systems, creating an integrated flow from solder printing and solder-paste inspection through component placement and final appearance inspection. Connecting these processes strengthens traceability, supports rapid feedback, and advances the plant toward increasingly autonomous production.
Looking Ahead
Working toward a fully unmanned production line, Alps Alpine will continue collaborating with SAKI to advance its assembly and inspection technologies. The next stage is to deepen equipment integration, make greater use of inspection data, and apply AI to reduce false calls and operator intervention even further.
Through its SPI, AOI, and AI solutions, SAKI will continue supporting Alps Alpine’s goals of autonomous production, higher equipment uptime, and consistently superior quality.