With the construction of a new printed circuit board assembly facility at its Zernsdorf site near Berlin, FSG has further expanded its in-house electronics manufacturing capacity. The new production area covers a total area of nearly 5,000 square meters. Since June, a total of 35 employees have been working there in two shifts to manufacture electronic components that are subsequently integrated into FSG's sensor solutions.

The actual production area comprises 1,800 square meters on the ground floor, including storage. This is roughly three times the size of the previous production of electronic components and circuit boards at the nearby plant in Kablow, which has now completely relocated to Zernsdorf. An additional 750 square meters of office space are located on the upper floor. The remaining area includes access roads, 66 parking spaces for cars, and green spaces, allowing the new facility to blend seamlessly into the design and architecture of the existing factory site.

Two production lines for automated printed circuit board manufacturing

FSG's new production facility features two lines for processing surface-mounted devices (SMDs), i.e., surface-mounted components used to assemble printed circuit boards. Line 1 (manufacturer: Mimot) can process up to 8,000 components per hour in PCB manufacturing, while Line 2 (manufacturer: ASMPT) can process up to 24,000 individual components per hour.

In the SMD area, new ASYS handling modules have been integrated – automation modules for the smooth handling of printed circuit boards within the production lines. A newly acquired modular stencil printer, type ASMPT DEK NeoHorizon 03iX, complements the existing EKRA printer. This ensures that the solder paste is precisely dispensed and positioned on both lines: In the precise manufacturing of these sensitive components, this is a critical step that is essential for the flawless operation of the printed circuit boards.

The two SMD lines are capable of efficiently producing large series as well as flexibly processing small batch sizes. The new plant is designed to accommodate a third SMD production line and additional automated inspection (AOI) systems if needed.

Modern warehouse logistics, room for possible expansions

FSG has also invested heavily in warehouse logistics, installing four Kardex shuttle systems, each 6.15 meters high. These automated high-bay racking systems utilize an electronically controlled extractor that transports the required storage racks (trays) directly to the access opening in a very short time and then efficiently stores them again. This results in shorter access times and significantly optimized warehouse processes.

For its building technology, FSG relies on systems that are both modern and future-oriented, such as heat pumps, heat recovery, and a photovoltaic system for generating its own electricity. The entire hall, including the offices, is air-conditioned.

Strengthened for the competition

With the new production facility, FSG is significantly expanding its capacity for the in-house manufacturing of electronic components. In addition to increased production capacity, the company will benefit from improved process stability and greater planning flexibility. "This will sustainably strengthen our competitiveness," says Managing Director Christian Schulz. "It provides us with a stable foundation for future growth and will help us successfully meet the increasing demands of the market."