Industry 4.0 is a phenomenon reshaping industrial production worldwide. At Gatema PCB, a leading European manufacturer of printed circuit boards (PCBs), this transformation integrates digitalization, automation, and cutting-edge technologies such as Artificial Intelligence (AI) and Digital Twin of Organization (DTO). These technologies significantly accelerate and enhance manufacturing processes, delivering added value to customers.
One of the core elements of Industry 4.0 at Gatema PCB is the extensive automation of production processes. Using the MES system REVA, manufacturing equipment such as drills, etching machines, and routers are seamlessly integrated with the HELIOS Nephrite information system. The system automatically uploads production programs for specific operations and delivers them to the machines, minimizing errors caused by manual input. Operators on the shop floor simply confirm the processing through a barcode scanner, allowing subsequent operations to proceed without unnecessary delays.
Digital transformation enables Gatema PCB to meticulously plan production and track the status of every order in real time. The Digital Process Adjustment (DPA) system recalculates production schedules hourly and updates data across all systems. This technology facilitates not only rapid short-term operational planning but also long-term optimization through the use of the company’s Digital Twin.
Thanks to these tools, Gatema PCB can respond flexibly to changing customer demands and quickly integrate new orders into production.
One of the most significant benefits of digitalization is the dramatic reduction in PCB manufacturing time. While production previously took 10 to 14 days, Gatema PCB can now deliver high-quality PCBs in as little as 14 hours, provided the input data is correctly prepared. This achievement results from a combination of process optimization, automation, and precise planning.
Digitalization extends to customer interactions as well. Gatema PCB utilizes an online order configurator that allows customers to precisely define the parameters of their orders. These specifications are then automatically transferred to the HELIOS information system, eliminating errors during manual transcription and reducing data preparation time. This streamlined process ensures that orders are quickly ready for production.
Artificial Intelligence (AI) and data play a critical role at Gatema PCB. AI algorithms analyze large volumes of production data, predict future needs, and identify potential issues. This helps the company streamline production processes, eliminate delays, and optimize costs.
For example, by analyzing data from the MES system REVA, AI identifies potential bottlenecks in production, allowing them to be resolved quickly and ensuring a smoother workflow.
As part of its Industry 4.0 implementation, Gatema PCB has modernized critical production equipment, including the installation of the Lauffer press system. This new press replaced a 30-year-old machine that was increasingly difficult to maintain and had limited capacity.
The new press system has revolutionized the production of multilayer PCBs. It supports pressing not only standard materials but also hybrid composites, high-temperature materials, flexible PCBs, and specialized boards with multiple laminations. This significantly expands Gatema PCB's technological capabilities.
In addition to increased technological flexibility, the new press also boosts production capacity. The system features a job queue function that allows continuous operation throughout an entire shift without operator supervision—known as a "ghost shift." This enhances production efficiency and shortens delivery times, a critical requirement in today's competitive market.
Another vital aspect of Industry 4.0 at Gatema PCB is the integration of a Warehouse Management System (WMS) with inventory operations. This system automatically plans and manages material distribution for specific orders. Data on material consumption is instantly synchronized with production processes, ensuring optimal stock utilization and eliminating waste.
The implementation of these advanced technologies was carried out at Gatema PCB without halting production, demonstrating meticulous planning and the professionalism of the entire team. Today, the HELIOS Nephrite system with its production module is used by more than 100 employees, significantly enhancing their efficiency.
Gatema PCB is not standing still. With the introduction of new modules like BERGHOF Adaptive/SRM and DPA, the company is moving toward even more flexible and reliable production processes. The goal is to continue delivering top-tier products and thriving in the highly competitive PCB market.
As Production Manager Radim Vítek explains: "Industry 4.0 allows us to better serve our customers, remain flexible, and maintain high product quality. These technologies prepare us for the future."
Industry 4.0 at Gatema PCB combines state-of-the-art technologies to automate and digitize manufacturing processes, shorten lead times, and deliver higher-quality services to customers. This approach not only boosts production efficiency but also positions the company to compete successfully on the global stage.
Automation as the Foundation of Modern Manufacturing
Digitalization of Production Control and Planning
Faster Production Times Through Innovation
Order Configurator as a Bridge to Customers
Efficient Inventory Management
Seamless Implementation Without Interrupting Production
