State-of-the-art production.
Highly qualified employees.

Quality made in Germany

In-house production with highly qualified specialists, state-of-the-art production and control systems and optimised logistics is one of the cornerstones of our philosophy Traditional. Innovative. SOLUTIONS. Our modular digital and analogue train radio systems (cab radios) are developed and produced at our Kölleda site. Our production flexibility ensures that we can fulfil the wide range of variants required by our customers. Assembly and test workstations specially designed for cab radios form the backbone of high quality.

Funkwerk attaches great importance to care, precision and quality throughout the entire production process. For example, following a comprehensive audit of the „Stationary customer information“ product group, Deutsche Bahn AG awarded Funkwerk 100 out of a possible 100 points (rating of „Outstanding“) in its supplier evaluation. A doubling of production figures between 2017 and 2019 demonstrates the flexibility and scalability of Funkwerk's production capacity. Additional resources were created by expanding the production area in 2021.

Facts and figures

Funkwerk has a fully comprehensive production process ranging from manual assembly for small and very complex runs to state-of-the-art, fully automated production systems - from PCB assembly to drying, coating and testing. In order to meet the project-specific requirements of our customers, individual cables or customised cable harnesses are assembled directly in-house.

In addition to development, the production of all PCBs and components as well as final assembly, testing and burn-in takes place at the Kölleda site. Modern AOI and computer-aided fault exclusion systems guarantee the highest possible quality of the assemblies throughout the entire production process. With a focus on sustainability, health and environmental protection, Funkwerk produces RoHS-compliant printed circuit boards that are completely lead-free.

The assembled circuit boards and modules for cab radio production and the components for the display systems are prepared for assembly at special workstations and integrated into the housings provided with the corresponding wiring.

All finished devices are subjected to an endurance test after a visual and functional quality check. This is followed by software updates or the installation of customer software. With a final system check, the devices are tested in existing systems and approved by our quality assurance department.

The pre-assembly and final assembly of all components and end devices also takes place in Kölleda, although the passenger information division has an additional production site in Karlsfeld near Munich.

> 130.000

printed circuit boards produced per year

50 to 1,300

Components per printed circuit board

up to 35,000

Placements per hour and module

Fully and semi-automatic PCB assembly (SMD, THT, wave soldering, selective soldering)

Semi-automatic placement at programmable placement stations
with incident light display and feed system

Manual assembly

Fully automatic PCB coating

Fully automatic drying

Mechanical component processing

Cable production and assembly (customer/project-specific)

Pre-assembly and final assembly of modules and complete devices

Endurance run (burn-in/run-in tests)

Commissioning

More than 130,000 PCBs produced per year with 50 to 1,300 components per PCB

100% AOI and electrically tested

Approved according to IPC-A-610H

8-16 hours burn in/endurance run (more possible by arrangement)

More than 250 cab radios produced per month

More than 1,000 display systems produced per year

75 employees in production, 15 of whom are circuit board and device testers

SMD assembly

3x fully automatic Fuji NXT assembly lines 25,000 to 35,000 components per hour and module

Precision solder paste printer

Stencil printer

Inline dispensing system

Minimum mounting form: Metric 0201

Accuracy: 25 μm (+/-)

Maximum height of SMD components 24.3 mm

Maximum PCB size: 400 x 508 mm

90 mm minimum panel width

98N maximum placement pressure

8mm minimum feeder width, 72mm maximum

Up to 225 feeder positions (8mm)

Reflow soldering oven ERSA EXOS 10/26 with vacuum

Automatic inline control
SPI System Kohyoung KY8030-2
AOI System Kohyoung Zenith 2

Vacuum module Ersa One - unique in the world, built to specifications.
No air inclusions, optimum coating results after 60s throughput time per PCB side

Inline drying oven Rehm RDS. After 60s, the PCBs can be installed and tested (incl. high-voltage tests).

THT assembly

2x ERSA Ecoselect 4 selective soldering systems

Shielding gas wave soldering system Seho MWS 2340

Mycronic THT assembly

LPKF CuttingMaster 2240P laser depanelling machine for clean edges

Frame transport system

A further two MIMOT SMD lines with two and three MB300 pick-and-place machines complete the SMD assembly, optionally with Rehm or Rehm Condenso XP reflow ovens.

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