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Cisel Achieved 400 Tests Per Hour with Automated PCB Testing

Case Study

6/16/2021

Automated PCB testing process for automotive circuit boards

Industry

Automotive

Application

Inspection

Robot Solution

OMRON TM5-900 Cobot

Faster, more consistent PCB testing with robotics

Cisel needed to improve the speed and consistency of PCB testing for high-reliability automotive components. Manual handling limited production throughput and increased the risk of errors in a process where quality and traceability were critical.

To address these challenges, Cisel partnered with OMRON to implement automated PCB testing using the TM5-900 collaborative robot. Equipped with integrated vision and auto-calibration, the cobot managed each step of the electrical testing process for power steering PCBs, including picking boards, placing them on the tester, and sorting approved or rejected units.

Safety was supported by the OMRON OS32C laser scanner, which automatically slowed or stopped the cobot when personnel approached. The system was coordinated by the OMRON NX102 controller, capturing real-time production data and supporting full traceability throughout the testing process.

With automated PCB testing, Cisel was able to test up to 400 boards per hour across two full shifts with zero human error. The solution helped create a faster, safer, and more reliable quality control process for demanding automotive applications.

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Results at a glance:

Up to 400 PCBs tested per hour
Complete traceability and automated data collection
Human error eliminated from PCB testing
Safe, collaborative work environment with laser-scanned protection
Scalable automation for future needs

Practical automation for PCB testing

PCB testing often requires a careful balance of speed, accuracy, and flexibility, especially as production volumes and product variations change. OMRON helps manufacturers apply automated testing solutions that support consistent results while reducing the demands of manual processes.

If your team is exploring ways to improve PCB testing efficiency or adapt to changing production needs, we can help identify an approach that fits your process.