Altronic LLC Transforms Its Material Management with Inovaxe Solutions

Based in Girard, Ohio, Altronic LLC has been a leader in the design and manufacturing of ignition and control systems for industrial engines and other specialty instrumentation applications for seven decades. The company was founded in the 1950s with a focus on developing cutting-edge transistorized continuous spark ignition systems. Since then, Altronic has significantly expanded its product line to include fuel controls and instrumentation, which cater to the needs of gas engine OEMs and operators across the globe.

Altronic’s dedication to providing top-quality, reliable products has made it a trusted name in the industry.

In 2009, Altronic was acquired by HOERBIGER Holding AG, a Swiss company, and it became a central part of HOERBIGER’s Engine Division business unit. This transition brought new opportunities for growth and innovation, and Altronic continues to play a crucial role in the development of high-performance solutions for natural gas-fueled engines and other specialty instrumentation applications. Through decades of engineering expertise, Altronic has maintained its commitment to quality, ensuring that its products meet the rigorous demands of customers around the world.

“As an OEM, Altronic takes great pride in being an industry leader,” said David Bulkley, Director of Manufacturing at Altronic. “Our customers rely on us for consistent product reliability, timely delivery, and exceptional quality. Achieving these standards requires flexibility and tightly controlled processes throughout our manufacturing operations.”

Recently, Altronic recognized the need for a complete overhaul of its SMT manufacturing equipment, particularly in the areas of component storage and material handling. According to Bulkley, the company had been facing ongoing challenges with its existing material retrieval processes. “In the early days of SMT, we had to manually search our ERP system to locate the materials we needed. We’d identify the shelf, find the right bin, and then track down the component,” Bulkley recalled. “As we continued to integrate more SMT designs, the need for more flexibility and efficiency became clearer.”

To address these challenges, Altronic initially implemented a hybrid solution by introducing storage towers to help with material retrieval and storage. The company began with a single storage tower while maintaining some traditional manual shelving systems. “This was an improvement compared to our previous setup, but we knew it wasn’t the ultimate solution,” Bulkley explained. The company quickly realized that a fully integrated system was necessary to optimize its manufacturing operations.

At the time, work-in-progress (WIP) materials were stored in the storage towers, while newly unopened reels were still stored in traditional shelving. Despite these improvements, the company faced several obstacles. Bulkley acknowledged that space on the production floor was limited, and the mechanical aspects of the storage tower system led to downtime on multiple occasions. “We often had to use ladders to manually retrieve materials from the storage towers, which would disrupt production schedules,” he said. “As a result, we began looking for a more efficient and streamlined solution.”

At this point, Altronic decided to take a holistic approach to component storage and material handling. The company’s goal was to create a system that would track and manage materials throughout the entire production process, from the moment they arrived at the facility to when they were placed back into stock. Additionally, Altronic needed a system that would improve inventory accuracy, manage various types of components, and ensure the proper handling of dry-storage materials.

“We wanted a comprehensive solution that would allow us to track material from the moment it entered the building, through its transfer within the facility, all the way to its return into stock,” Bulkley explained. “Given the variety of components we handle, including those with specific moisture–sensitivity levels (MSL), we needed a system that could accommodate all of these requirements.”

Altronic’s search for a suitable solution ultimately led them to Inovaxe, a company known for its innovative approach to material handling and storage solutions. “Over the years, we’ve seen Inovaxe at various trade shows and have noticed the consistent growth of their company,” said Bulkley. “Their technology and market presence impressed us, so we wanted to learn more about what they could offer.”

Inovaxe’s system and SMT solutions were put to the test when Altronic’s team traveled to Florida to visit Inovaxe’s facility. The team was given a detailed demonstration of the company’s end-to-end SMT solutions. The demonstration covered everything from the receiving process to the material handling, storage, and final material return. “We saw firsthand how Inovaxe’s technology could seamlessly integrate all aspects of the material management process,” Bulkley said. “The demonstration was incredibly informative and helped us see the full potential of the Inovaxe system.”

The Inovaxe system uses a unique combination of mobile racks, stationary racking, and dry storage cabinets, providing end-to-end material management. The receiving process begins with the MODI Table, a key component of the Inovaxe system. The MODI Table allows for the quick scanning of reels via a camera located beneath a glass window. The scan captures essential vendor reel data, which is automatically entered into the database. Once the reel’s data is captured, it is assigned a unique ID (UID) and stored in the system for traceability.

“We immediately recognized the benefits of automation in the receiving process,” Bulkley explained. “Not only does it reduce the chances of human error in data entry, but it also maximizes throughput and improves traceability across the entire manufacturing operation.”

Once the material is scanned, the mobile racks are used to transfer the reels to the stationary racking system. The mobile racks are designed to ensure that materials are not misplaced during the transfer process. Inovaxe’s software built-in process controls prevent the operator from scanning a new reel until the previous one has been physically placed onto the mobile rack. This feature ensures that the materials are tracked accurately and helps avoid the frequent issue of misplaced items that plagued Altronic’s previous system.

Upon arriving at the stationary racking system, the reels are placed into designated storage locations, making it easy for operators to access materials when needed. The software provides additional safeguards, alerting the operator if a process step is missed. This feature ensures that materials are always handled correctly and that operators adhere to established procedures.

Another key component of the system is the dry storage cabinet, which is integrated with the stationary racking system. Altronic handles numerous components that require precise moisture control, so having a dedicated dry storage system was essential. The Inovaxe dry storage cabinets automatically monitor the moisture levels of sensitive components. If a component exceeds its time limit outside of the cabinet, the system triggers an alert. Additionally, the cabinet features built-in heating elements that can return the components to specification, eliminating the need for external equipment. This automation significantly reduced the manual intervention required in Altronic’s previous setup, streamlining the process and improving accuracy.

Inovaxe’s integration with Altronic’s pick-and-place machines further enhanced operational efficiency. By customizing the software to interface with the company’s existing pick-and-place systems, Altronic’s team was able to optimize SMT job setups. The Inovaxe system generates a pick list and displays it on a tablet, showing operators the correct materials.

Operators use mobile carts to pick the necessary components, and as they proceed through the picking process, the system lights up the corresponding sections and components on the racks. Bulkley emphasized the value of this “pick-to-light” setup: “It makes it incredibly easy for operators to grab the right materials quickly and accurately. We no longer need to manually look up part numbers in our ERP system or search through bins for components.”

The pick-and-place system’s ability to accommodate different package types and material formats has further increased flexibility on the shop floor. “The system can handle various material types, including tube stock, which adds another layer of versatility,” Bulkley noted.

Once the components for a job have been picked, the next step is to set up the SMT process. Altronic’s streamlined workflow ensures that each cart is fully equipped with the necessary materials before the setup is complete. “We wanted to make the setup process as simple as possible for our operators,”Bulkley said. “By completing one cart at a time, from left to right, we’ve minimized the need for operators to search for components, helping to maintain process control and reduce errors.”

When the job is finished and the materials need to be returned to stock, Altronic uses the VisiConsult XRHCount X-ray system to accurately count the reels. The X-ray system communicates directly with Inovaxe’s software, updating the database in real time with the correct inventory count. “Previously, we faced many challenges with getting accurate counts after a job was completed,” Bulkley explained. “Now, with the X-ray system, we’re confident in our inventory levels, and our accuracy rate has skyrocketed to 99.9%. The ability to count a reel in less than 10 seconds has eliminated the need for manual counting methods.”

Bulkley concluded, “Inovaxe’s system has provided us with a fully integrated, holistic solution for material management. The software is intuitive and customizable, and it has given us greater efficiency, accuracy, and traceability. By automating key processes and improving inventory management, we are now able to better support our business needs while ensuring we meet our customer expectations.”

Altronic’s investment in Inovaxe’s advanced material handling solutions has proven to be a game-changer, enabling the company to streamline operations, reduce downtime, and enhance overall productivity. As the company continues to innovate and evolve, it remains committed to providing high-quality products and superior service to its global customer base.

For more information about Altronic LLC, contact David Bulkley, Director of Manufacturing, at 712 Trumbell Ave., Girard, OH 44420; 330–545–9768; Web site: www.altronic-llc.com