Fantastic factory in the forest

Customers, who have their medical devices manufactured by the company from California, do not just receive products which comply with the strict criteria of the US Food and Drug Administration (FDA) – they actually get a lot more. The founder and CEO of the company, Billoo Rataul, puts it like this: „Quality is decisive, but the Paramit experience goes much further: The motor for our corporate culture is the passion for constant improvement and smart problem-solving approaches. We consistently supply our customers with superb performance and peace of mind. Over many years, the team has developed an outstanding production standard by concentrating on printed circuit board production at Six-Sigma quality levels, combined with the patented vPoke system, which enables defect-free mechanical assembly. This computer-directed system breaks down assembly and testing of a complex product into hundreds or thousands of process steps, each of which is validated, verified, and documented. In assembly, we come very, very close to the zero-defect ideal – at a rate of under 1 DPMO (defects per million opportunities)! With a sophisticated 100 % in-line soldering process layout, 3D inspection of the soldering paste application, fast machine set-up for high-mix environments, multiproduct-single-setup algorithms, automated in-line inspection and process validation, we achieve an almost unbelievable quality level of 10 DPMO – by comparison: the highest IPC standard achieved in a high-mix low-volume environment is 30 DPMO.

Zero-defect approach, extreme performance

In addition to the current product range, the new factory in Malaysia will increasingly focus on medical devices– of course with the same zero-defect approach that also applies in the US, supported by a perfect mix of quality in SMT production, 100 % just-in-time delivery of finished products, and an efficiency level exceeding even the high Six Sigma specifications. From the ground up, the facility in Penang Science Park replicated the design, concept, and function of the US headquarters in California. Which also includes the seamless integration of the company’s own performance processes to better than best-in-class level in terms of quality, adherence to delivery schedules, customer service, and costs. The idea of an environment-friendly factory, perfectly adapted to the Malaysian climate, originated with the company’s CEO– the holistic concept and the design of the building were supplied by a French architect. Everything addresses environment-friendly energy efficiency – from the in-slab, water-based cooling system, to the climate-regulating effect of the shade created by the canopy of trees. The numerous plants are irrigated using rainwater collected in huge tanks located under the car parks. In addition, energy-saving LED lamps are used and the production facility is primarily supplied with natural light through large-scale windows. The Malaysian facility combines this environment-friendly approach with an open office concept with gardens and waterfalls on multiple levels and meeting spaces which, as required, provide more space or allow employees to work undisturbed.

The new 15,000 m2 factory is said to be Malaysia’s largest facility for the production of complex medical devices, realizing sophisticated systems for genetic and molecular testing, robotic surgery, and cancer treatment. Existing customers, for whom the company produces industrial products such as gas and fire protection systems, electrical and digital measuring devices, automotive heating elements, and agricultural management applications, will also benefit from the additional capacity. „Our expansion in Asia allows us to provide more sophisticated and tailored offerings to our regional customers – bringing new levels of speed-to-market and peace of mind to our customers,” says Mr. Rataul, on the strategic orientation in the Malaysian market, which is enjoying a particular boom in the medical devices industry – laterally displaying double-figure growth rates.

The greenest production in Malaysia

Back to the core of what is probably Malaysia’s greenest factory, the Paramit Malaysia manufacturing facility: „Of course, we were familiar with the concept of our new factory. But moving our 50 plant systems within just one day was still a major challenge. Nonetheless, we succeeded in setting up very quickly – with everything running smoothly within just one week,” says Chong Chit Leon, Section Manager Equipment Engineering. All production processes are subject to the highest standards – with the use of smart information and communication technology, such as automatic optic inspection (AOI) in order to uncover and eliminate any possible defects. “Our aim is to engage in dialogue with our customers at a very early stage in the product and board designs – allowing us to make our extensive engineering know-how available for efficient production. In this way, we achieve a speedy new product introduction and a shorter ‘time to market’, which is more economical for both sides,” adds Chong Chit Leon. The company in Malaysia is increasingly relying on the support of system supplier Ersa – since entering the market in 2011. Those responsible for production have ordered soldering systems for different requirements through the Singapore-based Ersa representative, Long Shine Equipment and Supplies Pte, which also looks after the Malaysian market. „For us as sub-contractors, the greatest benefit of the Ersa equipment is that it permits high-mix in every direction – for example, the Powerflow N2 full tunnel nitrogen wave soldering plant can handle all types of products. This gives us great flexibility in our manufacturing,“ says Chong Chit Leon. With the company’s strategic focus moving towards medical devices and life science instruments, and an increase of customer inquiries having also been received, more intensive attention was paid to selective soldering. Not only is this a high-performance and flexible soldering technology, it also fulfills all the criteria laid down for the high quality standards that apply in medical devices. Three companies were shortlisted during the purchasing process; in the end, the contract went to Ersa – specifically for the Versaflow 3/66 selective soldering system. In addition to the performance capacity of the plant, the link-up to corresponding service and support was a significant deciding factor. The team had also already seen and thoroughly tested the systems in the supplier’s showroom in Penang.

Soundly-based expertise for the soldering process

At present, Ersa’s worldwide presence is not all that decisive. In Malaysia, the main focus is on industrial products, with the recent addition of medical devices. Contact is mainly through the Long Shine representative in Singapore. “When it comes to the Ersa soldering expertise and the constant improvement of our processes, we work closely with the colleagues from Long Shine who are thoroughly familiar with the processes of the Ersa equipment,” says Chong Chit Leon. In order to maintain the good business relationship among the three partners, it is also important that wear and spare parts be available in Malaysia, for first and second level support. If the worst case scenario were to occur, Paramit would need immediate support, since spare parts are not stocked on site. Stocking these parts would be too expensive and the “right” spare would probably not be available right away. The team knows that, with the comprehensive process solution that is offered by Long Shine and Ersa, they are always on the safe side– first class service and support are definitely of the essence. As a global player, Ersa is undoubtedly a good partner for Paramit when it comes to further expansion plans.

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Ulrich Dosch is the Key Accounts & Business Development Manager for Kurtz Ersa Asia.