Digital television systems of NPO CTS

NPO Digital Television Systems OJSC is a large-scale electronic production in Russia. The capacity of the plant made it possible to open contract production lines, maintaining the previous volume of production of its own products. NPO "CTS" has the most modern equipment in Russia, which allows you to quickly switch from one product to another and carry out four-level quality control.

NPO "Digital Television Systems" is a platform for contract production of electronics of any type: industrial, automotive, household (consumer), electronics for housing and communal services, security systems and network equipment.

The area of ​ ​ production of NPO "CTS" is 13,000 square meters. m. The company operates automatic surface installation lines with a total capacity of more than 1 million components per hour. In addition, there are manual installation lines for pin components with a total capacity of 85,000 units per hour, as well as 6 conveyor lines of final assembly. Since 2018, the plant has mastered the production of more than 15 different types of motherboards for leading Russian computer manufacturers.

History

2024: GS Group invests 182 million rubles in modernizing electronics production

By the end of March, GS Group will invest 182 million rubles in modernizing the production of the CTS plant, a contract electronics manufacturer in the Kaliningrad region. The company announced this to TAdviser on March 14. The GS Group expects that the modernization will increase the installation speed of motherboards (including server boards) up to three times and increase labor productivity by 30% by the end of 2024.

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GS Group

By the end of summer, the plant will be supplied with the latest optical inspection devices with artificial intelligence. The AI will be responsible for checking the SMT installation (surface mount technology) when applying solder paste, the correct installation of components and the installation of components after soldering. The technology will reduce the preparation time for board production from 24 hours to half an hour.

According to Dmitry Fomichev, General Director of CTS, the use of AI in the manufacture of boards is a completely new experience for Russia.

In addition, as part of the modernization, the plant will ensure that the entire board soldering process is carried out in a nitrogen environment, which will reduce the number of defects to minimal values. To solder the output components, long-base furnaces will be installed, which will improve the installation quality of large server boards.

Improvements will affect the installation of components on boards. Additional computing power will allow you to prepare the next batch of products for launch without stopping the current process. Thus, it is expected that the downtime and preparation of equipment will be reduced by 80%.

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GS Group

According to Fyodor Boyarkov, vice president of production development at GS Group, modern production with the ambitions of the market leader needs regular renewal of capacities, which would be impossible without the proper conditions for doing business in the region.

"CTS" monitors the trends in the development of server equipment and is ready to fulfill the current requirements for server performance, releasing high-quality boards in even larger volumes. It's great that our vision for the development of production infrastructure coincides with the policy of the Ministry of Industry and Trade of the Russian Federation on the introduction of AI and modern automation methods, and our aspirations are actively supported by the government of the Kaliningrad region, he said.

2023:27% increase in motherboard production

In 2023, NPO Digital Television Systems (part of the GS Group holding), a Russian platform for mass contract production of electronics, manufactured 500,000 motherboards. Representatives of the GS Group reported this to TAdviser on January 26, 2024. For comparison, in 2022, the volume of board production amounted to 390 thousand units. Thus, over the year, this indicator increased by 27%.

source = NPO "CTS"

The increase in the number and volume of orders in GS Group is associated with the activity of domestic computer manufacturers, which are actively implementing the government's import substitution program.

"We see that Russian electronics manufacturers have seriously increased their presence in the domestic market," said Fedor Boyarkov, vice president of GS Group for production development. - This contributed to an increase in the load of contract production of boards. If in 2022 these were mainly boards for laptops, then in 2023 these are complex server boards, and boards of personal computers and even boards for telecom equipment. "

He also added that in 2024 the demand for contract production services will continue to grow. NPO Digital Television Systems has already signed contracts for the manufacture of almost a million motherboards in 2024. To fulfill orders, GS Group purchased an additional PCB installation line, which is scheduled for commissioning at the end of February 2024.

Large-scale production of computer motherboards on a contract basis was deployed at CTS in 2018. During this time, the company put into production more than 15 different types of motherboards for leading Russian manufacturers of computer equipment. Among the customers of NPO Digital Television Systems is the Russian manufacturer of iRU computer equipment.

2021: Plan to launch the production of computer components and peripherals

GS Group Holding on April 15, 2021 announced that, together with Philax Group of Companies, they are implementing a project to localize the production of electronic devices and components in the Russian Federation. The companies agreed to launch the production of computer components and peripherals in the Technopolis GS innovation cluster on the basis of the enterprise NPO CTS JSC. Read more here.

2020: Upgrade of Electronic Component Surface Mounting Line on Board

NPO CTS JSC (part of the Technopolis GS innovation cluster in Gusev Kaliningrad region) modernized one of the surface installation lines for electronic components on a board. Now the company has a surface installation line with automatic 3D inspection of solder paste and dual automatic optical 3D inspection (before and after soldering). The volume of investments in modernization exceeded 25 million rubles. This became known on October 12, 2020.

Leading manufacturers of computer and peripheral equipment have very high requirements for the quality of high-tech boards. World leaders demand from contract production the quality level of Zero Defects. The use of control equipment in production lines after all critical operations is mandatory at the moment; its absence from contract production is a blocking factor for companies placing an order.

According to the ASM Assembly Systems GmbH study, the quality of solder paste application is the source of up to 2/3 of all defects, therefore, control of the stability and repeatability of this process is of fundamental importance. 3D optical inspection takes place after installation of the components and before the board is fed into the melting furnace, allowing to control the accuracy of installation of the components until they are soldered and make adjustments without repairing the board. This is especially important for expensive or difficult to repair components - processors, expensive chips, sockets, etc. At the time of inspection, the board remains stationary, so the not-yet-soldered components do not shift.

NPO Digital Television Systems is actively developing in the contract production market. electronic engineers The company offers customers the production of high-tech boards for,, computers,, servers tablets mobile phones solid-state drives and other devices, as well as their assembly into finished products. In order to meet the requirements for product quality, we have completed one of the surface installation lines with two units for additional process control. We also supplemented the fleet with an automatic board separator. Thus, a line of surface mounting of the most complex boards for a variety of electronic equipment appeared at the CTS, "said Oleg Lobanov, General Director of NPO CTS.

The production of "CTS" is highly automated and ultra-productive, focused on mass production of products. As of October 2020, the company operates 5 automatic surface mounting lines: 3 Fuji lines, each of 14 modules, Assembleon and Yamaha lines with a total capacity of more than 1 million components per hour. In addition, the company operates 6 lines of manual installation of pin components with a total capacity of 85,000 units per hour, as well as 6 conveyor lines of final assembly. Up to 16 thousand complex products leave the conveyors per day.

2019

Among the top five Russian contract electronics manufacturers

On April 14, 2020 TAdviser , it became known that Russian Contract Electronic Equipment Market it grew by 26% in 2019 and amounted to about 20 billion (rubles about 300 million). dollars USA

A preliminary list of five Russian contract electronics manufacturers is presented below, sorted by market share.

• Microlite (HA Resonance)
• CTC (GS Group)
• A-contract
• PC Altonica
• StarLine

Read more here.

The CTS production capacity for April 2020 reaches 17 million finished products per year. More than 2.5 million receivers under the General Satellite brand are produced at the enterprise per year, design solutions, software and operating characteristics of which meet international standards.

Launch of another production line for surface installation of electronic components

GS Group announced in August 2019 the launch of another production line for surface installation of electronic components on a board at NPO CTS JSC (as part of the Technopolis GS innovation cluster, Gusev, Kaliningrad Region). Now the company is able to produce up to 1,440,000 devices per month with a decrease in the minimum batch to 500 units.

The CTS operates 5 automatic surface mounting lines: 3 Fuji lines, each of 14 modules, Assembleon and Yamaha lines with a total capacity of more than 929 thousand components per hour. The company also operates 6 lines of manual THD installation with a total capacity of 85,000 components per hour. Output installation is performed on AXIAL RADIAL THD automatic installers. Thanks to the commissioning of the fifth Yamaha line, the capacity of the enterprise increased by 10%. Investments in the expansion of production exceeded 30 million rubles.

"Our company has modern equipment that allows you to quickly switch production from one product to another and carry out four-level quality control. The launch of the fifth line of surface installation using SMT technology has reduced the volume of the minimum batch by almost half: now we are ready to produce electronics in small batches of 500 pieces. This will not only attract new contracts, but also make the process of pre-release of products for existing customers much more comfortable. Thanks to the new equipment, we will significantly reduce the costs of reconfiguring production lines, "said Repka Sergey, commercial director of CTS.

The production of "CTS" is highly automated and ultra-productive. Up to 16 thousand complex products leave the assembly line per day. The range of products produced is very diverse. In addition to digital set-top boxes, computer motherboards are produced at the facilities of the enterprise, solid-state drives, electronic meters and much more are assembled.

2017

Contract production: reaching the mark of 10 million products per year

NPO Digital Television Systems is a large-scale production of set-top boxes in Vostochny To Europe and a modern platform for contract production. electronic engineers

The plant's capacity made it possible to open contract production lines, maintaining the previous volume of products - digital set-top boxes under the General Satellite brand. The production of prefixes at the plant of JSC NPO CTS has reached 10 million. JSC "NPO" CTS "produces 2% of the world volume of digital set-top boxes.

Opportunities for Contract Manufacturing

• favorable geographical location;
• Special economic zone;
• import tax 0%;
• Quality management system is certified according to MS ISO 9001, environmental management system - ISO 14001;
• modern industrial equipment;
• compliance of production processes with IPC-A-610E - class II.

Technologies

Surface installation:

• BPM Micro 3800 - EEPROM Automated Programming System
• Two-way installation (Lead-free technology)
• Surface installation of enclosures from 01005 to microcircuits and non-standard components with accuracy up to 30 micrometers
• 3 Fuji NXT-II lines with a total capacity of more than 789,000 components/hour according to the IPC standard
• Up to 170 different component types installed
• Best-in-class ERSA HOTFLOW 3/20 oven
• Automatic optical inspection of paste application quality and automatic optical inspection
• Laser marking of boards for product inspection at all manufacturing stages

Lead-out installation:

• Delta 3 & 5 Wave Soldering Lines (Lead-free)
• High performance (25,000 components per hour) THD AXIAL\RADIAL UNIVERSAL installers
• 6 manual THD lines with a total capacity of 85,000 components per hour

Quality Control and Testing:

• Post Reflux Orbotech Optical Inspection S36
• Optical inspection of the quality of solder paste application by Orbotech P36
• X-Ray X-ray Inspection System
• Automatic In-Circuit (ICT)

and Functional Testing (FCT), 6TL

• Semi-automatic functional testing of finished products
• Vibration and temperature testing equipment

Production capacity - 5 million products per year

As of 2017, the company produces more than 2.5 million digital set-top boxes under the General Satellite brand per year, which is 2% of the world's volume of similar products.

Production facilities

• Production capacity - 5 million products per year (with an expansion to 10 million).
• Production area - 13,000 m2.
• The number of employees is 1,100.
• 3 automatic surface mounting lines, each of 14 modules.
• Lead-out installation - high-performance AXIAL RADIAL THD installers.
• 6 manual THD lines with a total capacity of 85,000 components per hour.
• Final assembly lines.
• Work on LeadFree technology.
• Production areas are protected from static electricity in accordance with IEC 61340-5-1/2.
• Quality control at all stages of production.
• Quality management system is certified according to ISO 9001:2008.

2014

JSC NPO "TsTS" has established a contract production of tachographs

NPO Digital Television Systems, a manufacturer of digital set-top boxes in Eastern Europe and a high-tech platform for contract production, has signed a contract with a large Moscow tachograph company . The capacities of NPO "CTS" OJSC made it possible to produce a product for the customer in large batches of tens of thousands of products.

The plant provides a full cycle of tachograph production - from PCB packing to final testing and packaging. The process involves both automated and manual operations. The company is equipped with modern equipment that allows solving complex problems in the production of electronic products, thanks to which the company was able to offer the customer the production of tachographs in large batches.

The technical equipment of the enterprise, engineering support, professionalism of personnel, flexibility in pricing and strict requirements for quality control played a decisive role in the fact that the customer chose the production of the GS Group holding to fulfill a large-scale order for the production of tachographs. Negotiations are currently underway to extend the contract between the partners.

Being one of the largest contract manufacturers of electronics in Russia, OJSC NPO "CTS" has the most modern equipment in the country at the moment, which allows not only to quickly switch production from one product to another, but also to carry out six-level quality control of products. Each subsequent operation checks the previous one, a number of operations in the production chain are completed by testing, at the final stage a final check is carried out.

"This year we began to actively work in the contract electronics production market, offering the capabilities of NPO CTS OJSC and the entire innovation cluster Technopolice GS, which includes our enterprise, as a universal production site," commented Alexey Goncharuk, director of contract production of Technopolice GS. "Many potential customers, having familiarized themselves with the flexible conditions and wide possibilities provided by us, decide to cooperate with us

Smart cards will be produced at Technopolice GS

A smart card production line has been opened at the NPO Digital Television Systems OJSC, which is part of the Technopolice GS innovation cluster in Gusev, Kaliningrad Region. At the end of December 2014, the release of access cards for subscribers of the leading Russian satellite television operator Tricolor TV began, in the future it is possible to expand the sales market at the expense of other customers.

For the production of smart cards at NPO CTS OJSC, a special room was allocated and equipment was purchased. Also, several employees who received the appropriate training were transferred to a new highly automated line. The total cost of the project was about 2.5 million euros. The new line allows you to produce a wide range of smart cards used in various industries: access cards, SIM cards, loyalty cards, etc. The company encodes chips, solders them into a plastic case and applies the image to the map.

The customer of smart cards is CJSC National Satellite Company (Tricolor TV brand). GS Group Holding, as a key technological partner of Tricolor TV, develops and manufactures a full set of subscriber equipment for receiving a satellite signal at Technopolice GS. However, access cards for Tricolor TV subscribers were previously purchased from another company that programmed chips for access to paid television. With the transfer of production to the capacity of Technopolice GS, chip coding will be fully provided by specialists of NPO CTS OJSC, which will increase the protection of devices from unauthorized copying of data, as well as reduce the cost of the finished product.

The planned production of smart cards for 2015 will be about three million units.

2007-2013

• 2013 - NPO "CTS" took first place at the regional competition "Russian Organization of High Social Efficiency," held in Kaliningrad, in the nomination "For Reduction of Industrial Injuries and Occupational Morbidity in Industrial Organizations."
• 2010 - NPO "CTS" began cooperation with Samsung Electronics.
• 2009 - the company has released a millionth digital set-top box.
• 2008 - CTS wins the Kaliningrad Brand 2008 Business Excellence Award in the Best Innovations nomination.
• 2007 - the foundation of the company "CTS."