Case Study: MAXIMIZING SINGAPORE EMS YIELD: STABILITY UNLOCKED

How a Singapore EMS Manufacturer Doubled Output While Reducing 2 Operators Using Controlled Automation

Customer Context 

• Industry: Electronics Manufacturing Services (EMS)  
  
• Location: Singapore 
  
• Application: Assembly process (previously fully manual)
• Production Environment: Output ramp-up phase

The customer was operating a fully manual process when production demand increased significantly — monthly output requirement doubled.

The Operational Bottleneck

With production volume doubling, the existing manual setup faced:

• Manpower constraints 
• Inconsistent quality between operators
• High dependency on individual skill 
• Scalability limitations

Increasing manpower was not sustainable due to labour cost and availability constraints.

The Requirement:  

Scale production while stabilising quality and reducing manpower dependency.

Solution Architecture 

Toki implemented a controlled automation system designed to replace the manual operation.

Key design objectives:

• Faster cycle time than current manual process  
• Stable, repeatable operation
• Minimal operator intervention
• Maintain or exceed required monthly output 
  

The machine achieved:

• 50% faster cycle time compared to the manual process
• Controlled and repeatable operation

Measured Results 

Post-implementation outcomes:

• Reduced 2 operators 
• Maintained required monthly output despite manpower reduction
• <5% reject rate
• Improved process consistency
• Higher production stability during ramp-up
  

The 50% faster cycle time allowed the automated system to absorb increased volume while reducing labour dependency.

Technical Impact Analysis

1. Cycle Time Reduction

Automation eliminated manual handling delays and variability, reducing process time by 50%.

2. Quality Stabilisation

Controlled operation reduced inconsistency between shifts and operators.

3. Scalability

Higher throughput capacity enabled production ramp-up without proportional manpower increase.

Strategic Business Impact

• Reduced labour cost
• Protected output during demand growth
• Improved yield stability
• Lower operational risk during production scaling

This case demonstrates that automation is not only about speed — it is about scalable control during growth.

Request a Process Evaluation 

If your production line is: 

• Struggling with manpower constraints
• Scaling output requirements
• Experiencing inconsistent quality 
• Heavily dependent on manual processes

Toki can assess automation feasibility to stabilise yield and increase throughput.

Speak to our automation specialists to evaluate your process.

Related Products:

• Toki Automation