Cobot completes one millionth PCB quality check
Hanover Displays, a UK-based manufacturer of passenger information systems for the public transport sector, has reached a major manufacturing milestone: the completion of its 1,000,000th automated quality test of printed circuit boards (PCBs) using Techman collaborative robots from LG Motion.
The automation programme began in 2018, when Hanover introduced its first collaborative robot to improve the accuracy and efficiency of testing electronic boards used in its LED passenger display systems. Working with automation integrator Absolute Robotics, Hanover deployed Techman collaborative robots to automate the repetitive and highly precise testing process.
Since then, the system has expanded significantly. Today, 11 Techman robots are installed at Hanover’s Lewes manufacturing facility, including TM5-900 and TM12 models, supporting continuous inspection and testing operations across multiple lines.
Automating quality control
Hanover Displays manufactures passenger information and LED destination displays used by transport operators worldwide. As the company brought PCB production back in-house, it needed a reliable way to test and inspect thousands of circuit boards each year. Previously, this process required manual handling and constant operator attention.
The introduction of collaborative robots transformed the testing workflow. Equipped with integrated vision systems, the robots load boards, operate test equipment, verify LED sequences and record the results of each test. This automation enables consistent cycle times and supports unmanned operation, including overnight production runs. The introduction of the cobots has gained significant data and insights to help improve their first-time pass rate from 94% to 99.5%, strengthened department collaboration, and enhanced how Hanover design and test new products.
Proven reliability over eight years
One of the most significant findings of Hanover’s cobot deployment has been the proven reliability of the Techman robots in daily production.
Reece Mills, Sales and Operations Control Manager at Hanover Displays, commented: “Since installing the first Techman robot in 2018, the reliability has been exceptional. In eight years of operation across our cobots, we have only experienced a single joint failure. That level of performance really demonstrates the quality and robustness of the TM robots.”
The collaborative robots have allowed Hanover to maintain extremely high testing accuracy while freeing skilled employees from repetitive tasks and enabling them to focus on higher-value production activities.
Partnership driving automation success
The automated testing solution was delivered by Absolute Robotics, an automation specialist and integration partner for LG Motion. Together, the companies developed a flexible system capable of handling the wide variety of board sizes and configurations produced by Hanover.
By combining collaborative robotics with custom tooling and automated test equipment, Hanover achieved significant gains in productivity and quality assurance, including improved traceability and the ability to run automated tests around the clock.
Reaching one million automated PCB board tests represents a major milestone for Hanover Displays and highlights the long-term value of collaborative robot automation in electronics manufacturing.
The project demonstrates how advanced robotics can deliver consistent quality, improved efficiency and long-term reliability in demanding industrial environments.
Visit the LG Motion website for more information
