ELDAT, a leading German manufacturer of radio systems for the home automation market, is using the ProgWorx device programming system from Adaptsys to speed the production programming of boards destined for use in RF transmitters for door opening systems.

Using the ProgWorx system, ELDAT has increased the throughput of boards from 1000 pieces per shift using manual programming to 34,000 per shift. ELDAT also cites other benefits in terms of worker satisfaction and the provision of production data for traceability purposes.

The size and complexity of the boards presented a considerable challenge for ELDAT’s production team. The boards containing the radio transceiver are mounted onto panels, each containing 60 boards and measuring 212.904 x 282.194 mm, while the devices being programmed included a mix of SiLab C8051F901 and Microchip PIC10F202 microcontrollers.

Initially, the devices were programmed manually, a process that was extremely time-consuming and led ELDAT into looking at alternative solutions. “One option we looked at was a fully automated production line”, says Roland Mante, ELDAT’s Production Manager, “but this would not only have been very expensive but also would result in low levels of job satisfaction for the workforce.” ELDAT also looked at the possibility of getting the chips pre-programmed by an outside supplier, but potential logistical problems and the resulting delays ruled out this option.

Having decided to introduce automated programming into the existing production set-up at Zeesen near Berlin in Germany, ELDAT then investigated possible suppliers, and chose Adaptsys following a demonstration at a trade show and follow-up meetings. “What we were looking for was not just a programming system but a complete solution in the context of our overall production environment”, says Roland Mante, “and Adaptsys was the only supplier that could provide this integrated approach through a single contact point.”

Adaptsys has worked closely with ELDAT on issues like communication and hardware/software integration to ensure the correct functioning of the system, and is now confident of the benefits that the Adaptsys system is providing.

ProgWorx is a software suite designed to improve the efficiency and traceability of device programming in electronics manufacturing applications. The software integrates with a range of different programmers, allowing companies to select the programming technology best suited to their needs.

The software also integrates with ERP and manufacturing systems through APIs, optimising business processes, reporting and the management of stock. A particular advantage of ProgWorx is the built-in traceability, which is particularly suited to the ELDAT product range where encryption data has to be added to the normal manufacturing information.

The productivity boost provided by the Adaptsys ProgWorx system has already prompted ELDAT to expand its production programming capability to handle an additional transmitter board.

“This system represented a big investment which we had to justify to our senior management”, says Mr. Mante, “but we are now seeing the benefits to the extent that we will have recovered the cost within the first year of operation.” And the workforce is much happier at having been relieved of the drudgery of repetitive manual programming.

ProgWorx is available for customers as a front-end software interface or, as in Eldat’s application, as ProgWorx ISP: a complete turnkey board programming station.