Tonfunk Gruppe

more than 60 years of experience as an electronics manufacturer

Experience gained over more than six decades has made Tonfunk a competent provider of complex production services as EMS. Well-known customers from the medical technology, automotive, computer and industrial goods industries and many other sectors rely on the quality and reliability from the Tonfunk Group.

The range of services includes prototyping and NPI, one-off production and large-scale production. Tonfunk can meet short-term peaks in demand as well as implement long-term production strategies.

Surface Mounted Technology (SMT)

Surface Mounted Technology is the basic technology of every modern electronics production. It stands for high integration and manufacturing quality with short production times. The range of our manufacturing capabilities includes all component shapes available on the market.

Tonfunk offers:

  • Processing of rigid, rigid-flexible and flexible printed circuit boards
  • Use of Siplace SMT production lines from the company ASM
  • Inline-3D-SPI systems from Koh Young (automatic optical paste print inspection)
  • Inspection during production with AOI and X-Ray systems
  • Processing of components from 01005 spectrum and µBGA package shapes included
  • Combination with power semiconductors often leads to special requirements in soldering technology or also for production aids such as stepped solder paste stencils.
  • Particularly critical requirements are supported by the Jetprint process.

 

Through Hole Technology (THT)

THT stands for "through-hole technology" and means the assembly of PCBs with wired components through metallized holes in the PCB. The combination of very small sensitive components and large components with high heat capacity brings great technological challenges. Therefore, Tonfunk GmbH Ermsleben relies on state-of-the-art machines for the implementation of a wide range of soldering processes.

The Tonfunk portfolio includes:

  • Assembly of rigid and flexible printed circuit boards of the most diverse materials.
  • Several wave soldering systems with a maximum soldering width of 400 mm and a height of up to 100 mm, extended by additional convection for process-safe processing of the most diverse component combinations
  • Selective soldering processes with mini-waves and lift-dip technologies
  • All soldering processes take place under nitrogen protective gas atmosphere
  • Systems for press-fit techniques with automatic path-force control
  • Inspection during production with AOI and X-Ray systems

 

Soldering technology

All soldering technologies used at Tonfunk are both RoHS-compliant and available as leaded soldering processes. This means that we are also able to manufacture particularly reliable infrastructure electronics.

The following processes are primarily used:

  • Reflow soldering with Rehm furnaces of the Vision series.
  • Several wave soldering systems from SEHO with a maximum soldering width of 400 mm and a height of up to 100 mm, extended by additional convection for process-safe processing of the most diverse component combinations
  • selective soldering with SEHO PowerSelective and INERTEC mini wave and stroke dip technologies
  • automatic reflow rework station
  • All soldering processes take place under nitrogen protective gas atmosphere

For further processes please contact us for a personal discussion.

 

Test engineering

As an EMS service provider, we pursue the goal of the highest possible test coverage so that no defects remain undetected. At the same time, the depth of testing must also make sense in terms of costs. In this context, the quality controls are carried out during the process in order to detect defects at an early stage and to further optimize the processes. In this way, if processes are stable, the depth of testing can be reduced and the costs can be lowered.

We increase the test coverage and reduce the test costs by using an adapted combination of different test methods from optical, ICT and functional tests, depending on the product and quantity. Paste pressure inspection (SPI) and automatic optical inspection (AOI) are mandatory for 100 % of the assemblies. For components with hidden solder joints such as BGA or QFN packages, X-ray inspection (X-Ray) is also used. In the in-circuit test (ICT), different tests can be carried out using a test adapter. This ranges from the classic ICT to programming, the boundary scan integrated in the test system to the function test when using a multi-stage adapter. For smaller and medium quantities, a classic component test is carried out using flying probe tests (FPT). Functional tests are used to check entire functional units of the assemblies.

Tonfunk already accompanies you during product development and develops an individual test concept.

 

Montage und High Level Assembly

We assemble and combine electrical, electronic, electromechanical and mechanical subsystems into delivery units of a degree of integration tailored to customer requirements. Laser marking of housings is also a process you can resort to with us.

The products are completed and shipped in customer-specific packaging, also with accessories. Direct delivery to your production facilities worldwide as well as to your end customers on request are part of our service package.

  • Assembly stations and logistics concepts
  • Nest production
  • Monitored torque screwdriver
  • Laser marking
  • Programming according to customer requirements

 

Painting/grouting

An important part of today's electronic products is the technical protection of the components against environmental influences. For this reason, as a full-service provider, we offer the coating and potting of electronics with a wide variety of fully and semi-automated painting and potting systems.

Like all of our services, this is also available as a single component from a sealed ESD environment.

Processes used:

  • Single and multi-component potting; with resins (epoxy casting resin, polyurethane casting resin), foams or silicones.
  • Spray painting (also selective and spray-free)
  • Dam & Fill
  • Underfill
  • Drag coating
  • Dip coating
  • Hand and brush painting
  • Component fixing

 

Traceability

Tonfunk uses one of the leading, holistically integrated traceability systems from CompControl. The traceability of the individual components and processes to each individually manufactured system as a unique specimen is thus possible.

Our cross-process CAQ system from the company IQS supports us from FMEA to quality monitoring of our manufacturing processes and products.

For non-connected systems, process and defect data acquisition is supported by our own product, the MoPad.

The combination enables transparent production and in-process online defect detection.

 

Obsolescence Management

Obsolescence Management refers to a structured and controlled management process to forecast and reduce the impact of product obsolescence. Tonfunk's obsolescence management strategy protects your products from unexpected changes and discontinuations. Getting started with our Obsolescence Management is completely straightforward and available at all stages of the product lifecycle, so your assemblies are protected from future events.

Our Obsolescence Management protects you from the following market risks:

In volatile and dynamic times, market risks occur more frequently, for which a structured management process is required. Thus, you can protect your products from the following risks through active obsolescence management:

  • Growing number of discontinuations
  • Shortening of service life
  • Lack of availability
  • Increasing life cycle costs
  • Cessation of production due to missing components
  • Increasing planning uncertainties

Talk to us, we will find solutions.

Sample construction

Our customers are often under great time pressure in the time-to-market. Between the innovative idea and the finished product, prototyping plays a central role in the development process of electronics.

We help to take into account the requirements for design for manufacturing and design for testability as early as the development stage. We proceed as unbureaucratically as possible and proactively point out possibilities for improvement. From quick engineering samples to near-series samples, you can always rely on us 100%. We build the first samples and prototypes quickly, flexibly and with high quality on our series production lines with simultaneous process testing. In doing so, we align our processes completely with the requirements and specifications of our customers. If the remaining time window requires it, we also manufacture overnight. Our production works in three shifts and is therefore available to you 24 hours a day.

After Market Service

Maintaining the supply of spare parts in particular presents various challenges, as our customers often have to guarantee spare parts for many years. Material availability is a particular challenge, as various components have a much shorter product life cycle to your desired spare parts supply period. In addition, manufacturing processes and production equipment must be adequately stocked. Older test systems must be very carefully kept in operation as well as maintained and calibrated.

Scope of Service:

  • Material availability, residual coverage.
  • Obsolescence management
  • Spare parts management
  • Adequate production facilities
  • Maintenance, calibration of test equipment
TONFUNK GRUPPE
Anger 20 OT Ermsleben
06463 Falkenstein/ Harz

Phone: +49 34743 50-0
Fax: +49 34743 50-256
E-Mail:info@tonfunk.de