Founded in 1979 by Gerardine Ferlins, Cirtronics is a New England-based contract manufacturer (CM) specializing in complex systems. Ferlins built the company on a philosophy that values customers, community, suppliers, and teams equally with profits. Over four decades later, this approach has fostered enduring customer relationships, a strong market position, and significant business growth. “Our focus is on the customer,” says Jim McCall, Director of Manufacturing, emphasizing how the team customizes manufacturing systems and services to exceed expectations.
While service to customers is at the forefront of Cirtronics’ business, he added that the company builds teams as well as products. “We purposefully extend our definition of ‘team’ to include each of the ‘Six We Serve’: Customers, Community, Suppliers, Environment, Employee Owners, and the Corporation. We value each team member and welcome their unique contributions, treating each other with respect, kindness, and honesty as the foundation of our business.”
Because of this focus, Cirtronics excels in manufacturing high-complexity, quality-sensitive products. Its expertise is in highly rigorous and regulated markets, including robotics, defense/military, security, industrial, and medical. The company has built its reputation by addressing customer and product requirements with precision, quality, and tight tolerances. Its core certifications include ISO 9001 and ISO 13485, and it is both ITAR and FDA registered.
Cirtronics specializes in systems, assemblies, and boards, building and integrating full mechanical and electro-mechanical systems. It has experience in customized configurations and complex box builds, calibration, and testing. It also builds sub-assemblies for customers that then are integrated into larger systems; however, McCall added that Cirtronics also can accommodate customers that choose to retain final assembly of their products in-house and outsource a range of advanced sub-assemblies to it. With multiple lines and automated inspection equipment, its expertise in building products for quality-sensitive applications begins at the board level.
“As your manufacturing partner, we offer tailored solutions. We engage early to help you create documentation, identify sourcing, and validate efficient build processes to successfully transition your product,” said McCall.
Cirtronics recently made strategic acquisitions to enhance its manufacturing capabilities. Steadfastly focused on customer satisfaction and operational excellence, the company recognized the need for maximum efficiency and flexibility, particularly in component storage. The company understood the importance of automation investment, specifically in material management of its reels and tray devices for acceleration in picking of kits, quicker return to stock, and more accuracy/fewer errors in support of its SMT lines.
One of the main pain points for customers in this space is finding a CM partner who can manage material effectively. The company searched for the right automation equipment to improve accuracy, efficiency and component traceability. McCall said that Cirtronics was looking for a best-of-breed solution to manage its SMT reeled components, with expanded capabilities for more material management. “Traditionally, pick-and-place vendors dominate the CM space, and we considered both semi-automated and fully automated solutions,” he added.
Not only was the company looking for a partner to help with the solutions, but it also needed a partner that fit its values and work ethic. “Cirtronics’ culture is built on relationships and choosing a supplier partner for this multi-level project was no exception – we needed a leading-edge technology partner that would work collaboratively with us through the process.”
Cirtronics took its time researching solutions as well as partners that best met its requirements of collaboration, communication, and aligned values and, ultimately, chose Juki Automation Systems. “Our interactions with the team at Juki have been wonderful, their service has been exceptional, and any questions or challenges we’ve faced have been readily addressed,” McCall said.
Cirtronics purchased three of Juki Automation’s ISM UltraFlex 3600 storage units, nine UltraFlex 3900 systems, three multi-interface modules (MIMs) that include reel storage and interfaces with elevators and X-ray counters, and three Nordson Assure Flex E X-ray Counters. McCall said that with this purchase, the company has noticed improved management, time savings, floor space savings, and reduced errors.
He added, “Although there was a significant cost difference for the Juki system, we felt that the controls, speed, ease of handling, and ability to fully manage all materials – in addition to the ability to attach the Nordson X-ray counters – made the complete setup far superior to any other systems available in the market. No other supplier offers such a complete package. This investment in our future material handling operations ensures our customers will continue to benefit from accurate inventory management, with a new level of sophistication.”
Cirtronics purchased the systems in June 2023, and the units were fully installed by April 2024. The systems are currently in the validation stage, with multiple testing milestones for the process with various products. Then, they will move into customer inventory integration and finally software integration. McCall said, “Our goals with the IMS UltraFlex 3600 units are to allow automatic picking of the reels, eliminate the manual process of counting, and improve the material shortage challenges that most CMs and their customers experience.”
Before purchasing Juki’s ISM systems, Cirtronics’ operators had to manually pick each reel and then return to stock. Additionally, counting was conducted manually, there was little RH control, and the reels took up a significant amount of floor space on manual racks. After the systems were added to the facility, however, McCall said this solution freed up floor space, reduced operator touch time and increased RH control.
Juki’s ISM products, along with the integration of Nordson Dage’s Flex E component counters, have helped Cirtronics reach its desired levels of innovation, accuracy, and efficiency. Its purchased systems handle 7″ and 15″ reels. UID labels are generated and validated using Juki’s “foolproof” feature in the software. Picture traceability can be obtained for those customers needing it. Kits are picked efficiently with zero errors in faster timeframes while operators perform other functions due to ESD case technology. Floor space savings have been realized and the ISM storage units have been relocated to the main floor where the SMT placement equipment is located. All material is stored in an RH-controlled environment, thus working within J-STD-033 and reducing risk for MSD devices. Automated counting of reel quantities is performed to control Cirtronics’ inventory using the Nordson DAGE component counters. These units are fully integrated with the storage units for full autonomy.
Cirtronics recognizes that one of the biggest challenges within the industry is the management of inventory, with OEMs and other product companies looking to contract manufacturers to help address this industry-wide challenge. The Juki systems demonstrate Cirtronics’ commitment to continuous improvement and the execution of its technological roadmap while addressing this problem directly. The new systems will generate UIDs for every reel for more accurate tracking and traceability throughout the facility. This will also significantly increase the speed of storing and dispensing materials, allowing all SMT processes to run more efficiently, from receiving and beyond. The Juki systems also will reduce the overall facility footprint of SMT-reeled material and improve control over moisture-sensitivity levels (MSL).
The systems enable non-touch counting of reeled components and real-time material requirement planning (MRP) adjustments for inventory accuracy. This empowers Cirtronics to enhance customer service through greater inventory control, leading to faster deliveries and reduced run times in automated placement processes. Additionally, it provides opportunities for employees to learn various aspects of the material process. The company is committed to streamlining time-consuming tasks and promoting cross-training in technical functions, thus continually improving its team’s capabilities.
“The Juki systems help differentiate us in the industry amongst CMs of our size. Our customers will know we will do everything in our power to ensure they get the best possible product. We take pride in providing high-quality services and processes that support their success,” concluded McCall. “Cirtronics’ dedication to continuous improvement means we will continue to grow and enhance our operations, now with greater automation and throughput efficiencies thanks to the team at Juki.”
To find out more about Juki Automation Systems, visit www.juki-smt.com.
