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Game Changer Automation: THT Can Also Be Smart!

Heike Schlessmann — Tue, 09 Dec 2025 14:43:51 +0000

How Automated THT Manufacturing Pays Off and Boosts Competitiveness.

Electronics manufacturing is under pressure: product customization and market dynamics demand maximum flexibility while maintaining consistent quality. In the THT sector in particular, it is apparent how much economic success depends on well-designed automation.

No two cars are alike today, modern control technology is built to order, and industrial electronic components are individually tailored to customer requirements – to name just a few examples. At the same time, sales markets fluctuate noticeably, whether due to economic effects, geopolitical influences, or changing customer needs.
The increasing individualization of products and unsteady market demand place high expectations on electronics manufacturing: it must not only be flexible enough to produce a wide variety of assemblies and variants economically but also must be able to efficiently manufacture large series and small, specialized quantities – all while maintaining consistently high quality.
The challenge lies in striking a balance between flexibility, speed, and cost efficiency under increasingly complex conditions.

The demands placed on modern electronics manufacturing often clash with reality, and in addition to technological requirements, the human factor is increasingly coming into focus.
While automated processes are already established in other areas of electronics production, many process steps in THT manufacturing are still carried out manually. This is precisely where bottlenecks are increasingly occurring: skilled labor shortages, absences due to illness, rising wage costs, and higher error rates are putting pressure on production, especially when order volumes fluctuate. In addition, manual tasks affect cycle times and make complete traceability difficult, as processes cannot be recorded digitally throughout.

Step-by-step automation: Tailored to individual needs and scalable

One solution lies in the gradual, demand-oriented automation of THT manufacturing. Finding the right balance is key: complete automation is not always necessary, but targeted partial automation can already achieve noticeable effects – for example, in reducing errors, ensuring consistent quality, or maintaining a stable cycle time.
A scalable approach is essential, whereby the degree of automation can be adapted to the current workload and the vertical range of manufacture.
Equally important is a coherent concept for the interaction between operating personnel and the system. Ergonomic workplace design, simple operating concepts, and clear interfaces between humans and machines promote acceptance and increase efficiency.
When considering the automation of a production area, the future viability of the system should also be taken into account. A flexible concept must be able to accommodate changes in the product life cycle: increasing quantities, additional variants, or a higher degree of automation should be achievable without fundamental modifications.

Individual solutions

THT production lines are rarely standardized but are usually designed individually. The reasons for this can vary greatly and are determined by the products being manufactured, spatial conditions, and human resources. An off-the-shelf automation solution is therefore not very effective. It is crucial to analyze current requirements precisely to develop a concept that fits both the product portfolio and the long-term strategy of the company. In the best-case scenario, the result is a production line that can be expanded, i.e., that grows with future requirements, whether through the integration of additional workstations, the connection of further automation units, or integration into smart production networks.
This results in demand-oriented scaling and a phased investment. At the same time, the personnel on the production line are “taken along” step by step.

THT automation in practical application

A practical example shows what such a solution could look like: SEHO has implemented a complete THT production line with automatic soldering frame management for an electronics manufacturer on an area of only 120 square meters.

The entire line concept, including a SEHO wave soldering system, is arranged in U-shape and designed for high production volumes. To use the space as efficiently as possible, the eight assembly workstations required were arranged in four opposite positions, each using a shared main transport segment to the manufacturing line.
Ergonomic considerations were a key focus when planning the workstations, with individually height-adjustable tables, tiltable units for assembling components, material storage areas, and line side racks in which the assembly components are arranged clearly and within easy reach. From a logistical point of view, the integrated line side racks also offer the advantage that they can be set up anywhere, thus avoiding unnecessary interruptions.

Once a PCB is fully assembled, the soldering frame is transferred from the workstation to the main transport system at the touch of a button by a handling unit, fully automatically and with automatic height adjustment. Each assembly passes through a THT AOI system, which enables complete inspection of assembly quality. Defective assemblies are identified via a separation station and automatically returned to the original workstation, while correctly assembled boards can proceed directly to the wave soldering system.
After the soldering process, the soldered assemblies are lowered to the return conveyor level and pass through the AOI system again for solder joint inspection. Fault-free soldering frames are then transported to the respective workstations. A central rework buffer, in which faulty assemblies are buffered until further processing, prevents backlogs.

The path of the soldering frames within the manufacturing line is automatically controlled via RFID. As an alternative, the line can be equipped with barcode readers or other identification systems.

The degree of automation of such a production line can be flexibly expanded, for example, by using lightweight robots for assembly, which can be integrated centrally into the manufacturing line or decentrally at individual workstations.
Driverless transport systems (AGVs) also offer potential: they ensure a continuous flow of materials and take over the automated transport of assemblies to the next step in the manufacturing process.
This approach can gradually increase overall production efficiency while relieving operating personnel of non-value-adding activities.

Automated complete solutions

Automated complete solutions that virtually eliminate the need for manual intervention can make the production of THT assemblies even faster and more precise.

In one such project, SEHO developed a fully automated production cell in which all process steps are automated.
This includes assembly with subsequent automatic inspection, insertion of assemblies into workpiece carriers, automatic carrier closure, unloading of workpiece carriers after soldering, solder joint inspection and final automated pass/fail sorting – all without personnel involvement.
The assemblies processed in this system are also controlled via a code reading system connected to a host computer.
This results in a fully digitized process offering maximum transparency, consistent quality and minimal personnel requirements.

Conclusion: THT automation ensures productivity and competitiveness

The appropriate level of automation required depends on the specific application. Not every production line needs to be fully automated. It is more important that the chosen solution is suitable for the product, budget and planned development of the production site.
Scalable automation opens up the possibility of moving toward the future with a step-by-step investment – starting with basic automation and progressing to a fully automated production line. It is worth considering future expandability from the outset of the planning phase. The more prepared the system is, the easier it will be to integrate future requirements, whether due to increased quantities, new product variants, or additional process steps.

The benefits are obvious: automated processes ensure stable workflows and shorter throughput times, significantly increasing overall efficiency in production. Sources of error that can occur in manual processes are reduced, with positive effects on product quality and rework. They relieve staff of repetitive tasks and enable complete traceability.

For electronics manufacturers who want to remain competitive in the long term, automation in the THT sector is therefore becoming a strategic factor.

Want to learn more?
Visit our Automation page.

FAQ about Automation in THT Manufacturing

What specific problems does automation solve in THT manufacturing?

Automation eliminates typical bottlenecks such as staff shortages, fluctuating cycle times, and high defect rates in manual processes. It ensures more stable processes, end-to-end traceability, and minimizes downtime, which can quickly become critical when order situations change.

Why is THT more affected than SMT or other process steps?

While SMT manufacturing lines have been highly automated for years, THT manufacturing involves many manual steps, such as handling of soldering frames, assembly, and quality control. This results in greater dependence on staff availability and manufacturing routines. Automation reduces precisely this variability.

At what point does partial automation become economically viable?

Even individual steps such as automated soldering frame handling, inline AOI, or ergonomically standardized assembly workstations significantly increase process stability. These investments quickly pay for themselves, especially with changing quantities or variant production, because they reduce scrap and make throughput predictable.

Why does scalability play a central role in THT automation systems?

Conditions are changing: product variants, batch sizes, vertical range of manufacture. A scalable concept enables the integration of robots, AGVs, or additional workstations at a later date without having to rebuild the basic structure of the line. This reduces future investment risks and makes it easier to balance the peak loads.

Why are individually planned THT lines often more economical than standard solutions?

THT products differ in terms of geometry, weight, thermal requirements, and handling. Standard systems quickly reach their limits here. A customized solution optimizes material flow, space requirements, transport concept, and user interfaces precisely for the respective product portfolio, thereby achieving higher OEE values.

What does the practical example of an automated SEHO THT production line show?

The production line, which covers just 120 square meters, combines a U-shaped layout, ergonomic assembly workstations, automatic soldering frame transfers, a THT AOI with component placement control and solder joint inspection, and a wave soldering system to form a continuous production concept. The automatic return of defective assemblies and the management of soldering frames via RFID ensure high process reliability and clear material flows.

What are the advantages of a fully automated production cell?

In fully automated THT production cells, all process steps – component placement control, workpiece carrier handling, soldering, AOI, sorting – run without manual intervention and are fully digitized. This results in reproducible quality, stable cycle times, reduced personnel requirements, and clear traceability throughout the entire process.

How does automation increase the long-term competitiveness of a manufacturing site?

Automated processes ensure improved cycle times, less rework, and high machine availability. At the same time, employees are relieved of non-value-adding activities, allowing them to focus on skilled tasks. This helps to maintain production even during periods of labor shortages and cost pressures.

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Selektiv-Lötmaschinen

Selective Systems

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Wellen-Lötmaschinen

Wave Systems

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Reflow-Lötmaschinen

Reflow Systems

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PowerVision THT-AOI

Placement Control

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Automatisierung

Automation Technology

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SEHO at productronica India 2025

Vivien Schöllkopf — Wed, 27 Aug 2025 13:59:55 +0000

SEHO Systems India will exhibit at productronica India 2025, taking place from September 17 – 19, at the Exhibition Centre (BIEC), Bangalore International.

Visit us at booth H4.D51 and meet the SEHO experts to discover our latest innovations in soldering technologies and automation solutions.

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Participation in the FORnanoSatellites Research Project – Future Technology for Small Satellites

Vivien Schöllkopf — Thu, 24 Jul 2025 07:57:09 +0000

We are a partner in the FORnanoSatellites research project, coordinated by Friedrich-Alexander University Erlangen-Nürnberg (FAU) and funded by the Bavarian Research Foundation with approximately 1.8 million euros. The aim of the project is to develop innovative technological components for small satellites and to establish an automated small-batch production in Bavaria.

Our role in the project focuses on interconnection technology: we support the research partners in developing system-in-package solutions using additive metallization to efficiently integrate electronic and mechanical components in highly compact spaces. This enables us to contribute significantly to improving the compactness and performance of small satellites. The close collaboration with universities, research institutions such as the German Aerospace Center (DLR), and other industry partners offers us the opportunity to further develop our technology in a practical context and tailor it to new applications.

FORnanoSatellites not only strengthens technological independence in the aerospace sector but also boosts the innovative capacity of small and medium-sized enterprises in Bavaria – we are proud to be part of this forward-looking initiative.

Photo credit: (FAU/Harald Sippel)

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SEHO Systems and SMT Thermal Discoveries together at Productronica 2025

Vivien Schöllkopf — Wed, 23 Jul 2025 09:21:19 +0000

SEHO Systems and SMT Thermal Discoveries will exhibit jointly at Productronica 2025 in Munich. The two specialists in electronics manufacturing will combine their expertise and strengths and welcome visitors from November 18th to 21st, 2025, in Hall A4 at Booth 578.

Selective soldering, wave soldering, reflow soldering, reflow soldering with vacuum, automatic optical inspection, automation technology, temperature treatment, soldering systems for power electronics using formic acid: Experts welcome you on over 200 m² of exhibition space to provide information and advice on the latest technologies in these areas.

In addition to established reliability – with low maintenance requirements – energy efficiency and individual adaptation to specific customer needs are the special focus of the latest product generations.

Plan your visit now, we look forward to seeing you!

SEHO Systems & SMT Thermal Discoveries

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BIT – Wertheim 2025

Vivien Schöllkopf — Wed, 02 Jul 2025 05:58:41 +0000

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Energy Efficiency Amid Growth – Our Environmental Performance Speaks for Itself

Vivien Schöllkopf — Wed, 23 Apr 2025 14:12:59 +0000

At our company, sustainability is not about standing still – it’s about purposeful progress. While we have experienced growth in recent years, our energy consumption has notably declined.

Over the past five years alone, we have reduced our energy usage by more than 27% – a testament to what can be achieved when efficiency and responsibility go hand in hand.

We have also made substantial progress in reducing our heating requirements: Since 2021, we have lowered our gas consumption by more than 30%. This achievement was not the result of major investments, but rather of conscious, collective action in our daily routines. Initiatives such as transitioning to a four-day workweek, offering flexible remote work options, and raising awareness among employees – supported by a few strategically placed reminders on thermostats – played a key role.

At the same time, we are increasingly investing in renewable energy. Our photovoltaic systems now make a valuable contribution to our self-sufficiency by supplying clean electricity – straight from the roof into our daily operations.

For us, one thing is clear: economic success and climate protection are not mutually exclusive. On the contrary – they are closely interconnected.

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Azubi For Future 2025

Aylin Özbasaran — Tue, 08 Apr 2025 05:43:14 +0000

The event in Wiebelbach entered its second round – and SEHO was back on board!

On March 28, 2025, it was time once again: the second edition of Azubi For Future took place in the Wiebelbach industrial area – and of course, we were there too. Together with seven other companies from the area, we offered young people exciting insights into a variety of apprenticeships and dual study programs. We were especially pleased to welcome one more company as a new participant this year, a clear sign of how well the event was received the year before.

Experience professions up close

The idea behind Azubi For Future is simple but powerful: visitors get the chance to experience everyday work life in different companies, take a look behind the scenes, and connect directly with the people who work there. In addition to our training teams, our current apprentices were also on site to answer questions and share first-hand experiences. The event didn’t just showcase traditional apprenticeships, but also highlighted a wide range of dual study opportunities.

Our contribution – interactive, informative, and engaging

We made sure to offer a well-rounded experience at our company once again this year. Visitors could explore a career decision aid, designed to help them discover which profession might suit them best, along with conversation cards to make it easier to get talking. Our robotic arm was a real eye-catcher – it stamped the visitors’ contest cards automatically.

We also set up an interactive code puzzle, where participants could uncover interesting facts about our company in a playful way. One of the major highlights was the guided company tour, taking guests through our production area, warehouse, administration, and Democenter. We offered in-depth, hands-on explanations of our machines and their components – a real behind-the-scenes experience designed to inform and inspire.

Final stop: the checkpoint and prize draw

The event concluded at the central checkpoint, where visitors could enjoy refreshments, tasty food, and take part in the grand prize draw. Anyone who had collected at least five stamps from participating companies could drop off their contest card for a chance to win. The top prize was an e-scooter, followed by a stand-up paddle board and a Bluetooth speaker.

Thank you to everyone who took part

We would like to extend a heartfelt thank-you to everyone who helped make this event a success – from the organizers and participating companies to all the visitors who joined us and got involved. We’re already looking forward to the next Azubi For Future and hope to welcome many curious young minds to SEHO again soon.

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The 4-day workweek for the whole company

Aylin Özbasaran — Mon, 09 Dec 2024 14:35:41 +0000

Turn five into four – SEHO is doing it again!

Sustainable change, real innovation: SEHO Systems GmbH from Kreuzwertheim continues to write the success story of the 4-day workweek. This modern working time model was successfully introduced for production and warehousing back in 2022. Now the administration and technical departments are following suit from 2025 – and SEHO is once again proving that entrepreneurial success and a modern working culture go hand in hand.

At a time when the shortage of skilled workers is presenting many companies with challenges, SEHO is focusing on a strategy that puts people first. The working week is reduced to 37 hours – spread over four working days, with full pay compensation. “We have already noticed after the introduction in 2022 that our productivity has not deteriorated despite the reduced working hours. On the contrary, it has actually increased,” explains Managing Director Markus Walter. Larissa Hepp, Head of Human Resources at SEHO, also emphasizes that the 4-day workweek concept has met with a positive response: “The number of sick days and the fluctuation rate in the affected departments remain at a low level and even show a significant improvement compared to previous values.”

A model with many advantages

The introduction of the 4-day workweek not only serves to increase the company’s attractiveness as an employer, but also contributes to a better work-life balance. More free time for employees also means more energy and motivation for work. In addition to these social aspects, the model is also environmentally friendly: fewer working days mean fewer commutes and therefore a reduction in CO₂ emissions.

Successful pilot project as a role model

SEHO launched the 4-day workweek in production and the warehouse back in 2022 – and the experience has been consistently positive. Rotating working hours meant that important processes such as deliveries and production were also ensured on the “days off”. The same degree of care has now been taken in planning the implementation in the administration and technical areas. “Our employees wanted more flexibility and modern working models – and we are proud to be following this path consistently,” adds Larissa Hepp.

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