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.

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Designed for manufacturers, engineers, operations leaders and automation professionals, Lean Robotic Automation provides a clear and practical framework for implementing robotics successfully, combining proven Lean principles with real-world automation experience.

With many businesses under pressure to increase productivity, improve consistency and address skills shortages, robotic automation is increasingly seen as a key enabler. However, automation projects can still be delayed by complexity, unclear requirements and avoidable inefficiencies. In Lean Robotic Automation, Livingstone explains how a Lean approach can help teams deploy robotic systems faster, reduce risk, and maximise return on investment.

“Robots can deliver incredible results, but only when they’re applied in the right way,” said Gary Livingstone, Managing Director of LG Motion. “This book is about taking a structured, Lean approach to robotic automation so projects are simpler, outcomes are clearer, and businesses get real value from their investment.”

The book covers key stages of the automation process, from early-stage planning and process evaluation through to implementation and continuous improvement, helping readers avoid common pitfalls and make informed decisions on where and how robotics can deliver measurable benefits.

Launch Offer: 50% Off Until End of May 2026

To celebrate the launch, readers can receive 50% off Lean Robotic Automation for a limited time until 31 May 2026 when purchasing via the LG Motion webshop. Use discount code: 5V6JSS4B.

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Visitors will see a Techman Robot collaborative arm integrated with OnRobot grippers and tooling, all controlled and engineered by LG Motion. The demo replicates a realistic production process, highlighting accuracy, speed and flexibility in handling components for manufacturing environments.

Unlike static displays, this demo combines camera vision, AI capabilities and adaptive gripper technology to perform highly precise automated movements. Techman’s built-in vision system, paired with OnRobot’s advanced tooling, allows for seamless detection, handling, and placement of objects with repeatable accuracy. It demonstrates how plug-and-play robotics can be deployed quickly for diverse applications – from education and R&D through to production environments.

This is a chance to experience cutting-edge robotics in a real-world scenario. Visitors will see how LG Motion integrates advanced robots, grippers and control systems into practical automation solutions that improve productivity and reduce manual handling. The stand will give engineers, production managers and academics alike the opportunity to explore how flexible robotics can be applied to their own projects – with LG Motion’s expertise available to discuss tailored solutions.

MachineBuilding.Live takes place at the NAEC Stoneleigh Park in Warks on 15 October 2025. You can register here to attend.

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As highlighted by ‘The Robot Queen’ and robotics expert Vanessa Loiola, the standard no longer uses the terms ‘collaborative robot’ or ‘collaborative operation’, emphasising that only the application can be designed, verified and validated as collaborative.

This reflects a major conceptual shift in how robotic safety is defined. The updated ISO 10218-1 and 10218-2:2025 standards now focus on a risk-based approach that encompasses the entire robot system, including the end-effector, workpiece, and surroundings. It also introduces more stringent guidelines for validation procedures, safety-rated soft axes and stops, and highlights the growing importance of safety integration during the design phase rather than post-deployment.

This change underscores the importance of comprehensive risk assessments and system-level safety validations over relying solely on robot labels. Safety is no longer just about the robot being ‘collaborative’ – it’s about the collaborative design of the entire application.

Your trusted partner for Techman Robot integration

As the authorised UK distributor and integrator for Techman Robots, LG Motion is at the forefront of delivering application-centric automation solutions. The company’s expertise and experience ensures that each deployment is tailored to meet specific safety and operational requirements, aligning with the latest industry standards, including the updated ISO 10218:2025.

Techman’s range of robots come equipped with built-in AI vision systems, enabling tasks such as quality inspection, pick-and-place, and assembly with high precision. A range of robots offering payload capacities from 5 kg to 30 kg and reach up to 1902 mm can cater to a huge range of applications across various industries.

With over 20 years of experience in the design and manufacturing of advanced motion control solutions, LG Motion is a trusted partner for businesses across science and industry. LG Motion’s deep engineering expertise, coupled with a commitment to precision and innovation, enables the company to deliver bespoke automation systems tailored to the most demanding applications. From cutting-edge research laboratories to industrial production lines, LG Motion’s solutions enhance performance, reliability and efficiency. By choosing LG Motion, you’re not just investing in high-quality products; you’re gaining a long-term partner dedicated to your success through technical excellence and outstanding customer support.

Comprehensive integration services: From initial consultation to full system integration, LG Motion provides end-to-end solutions that encompass mechanical design, control systems and safety validations including support.

Commitment to safety and compliance: LG Motion’s integration processes prioritise safety, ensuring that each application complies with the latest ISO standards and industry best practices, particularly in light of the 2025 updates.

Explore the Techman Robot range

Discover how Techman’s robots can enhance your operations by visiting LG Motion’s dedicated website: techman.lg-motion.co.uk. Here, you’ll find all the latest information on our product offerings, case studies and the various applications these robots can support.

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Simply put, LG Motion makes things that go in and out, up and down, round and round. The company designs, engineers and supplies a wide range of electro-mechanical motion control systems.

The portfolio includes precise, reliable, multi-axis motion control components both standard and customised, that are used in a wide range of scientific and industrial applications, from the film industry to space and everything in-between.

The core of LG Motion’s business is experience, knowledge and a pragmatic approach to providing motion technology solutions. Working hand-in-hand with customers, LG Motion’s bespoke solutions help enable research, development and manufacturing to move forward.

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Businesses are bearing the brunt as the UK economy battles to contain various pressures both at home and abroad. A weak pound, higher interest rates, increased energy costs, supply-chain issues and labour force shortages continue to create challenges, following the significant recent events of Brexit, Covid and the war in Ukraine.

Owing to uncertainty around global supply chains and costs, some companies are looking closer to home, bringing manufacturing and logistics functions back to the UK.

Along with a current stretch on the availability of talent, one area of development starting to see shoots of uptake in the UK is the use of robots and autonomous systems.

Until now, UK businesses have failed to capitalise on the opportunities presented by automation with industrial robots in the UK. Research by Boston Consulting Group in 2019 suggests that there is a significant gap between the ambitions of companies to implement robots and the actual implementation of systems.

Based on ABI Research (2020) robot shipments forecasts, analysis suggests that the total UK market for robots and automated systems will grow at a compound annual growth rate of more than 40% annually between 2020 and 2030.

But the fact remains, productivity in the UK has been sluggish since 2008/09, and lower than many peer economies, such as the United States, Germany and France. In 2015, the UK had 10 robots for every million hours worked, compared with 131 in the US, 133 in Germany and 167 in Japan. By 2017, the UK represented just 0.6% of industrial robotics shipments.

With current social trends of an ageing population and low birth rates in the UK, growth in labour productivity is essential. A recent study from Oxford Economics (2019) estimates that boosting robot installations to 30% above the baseline forecast by 2030 could lead to a 5.3% boost in global GDP (approximately $4.9 trillion per year by 2030).

This would mean an estimated impact of 15% of Gross Valued Added (GVA) in the UK – more than £200 billion – and a potential manufacturing sector productivity rise of up to 22%, generating long-term employment increases of up to 7% (cited by Special Interest Group Robotics and Autonomous Systems, 2014).

Robotics and autonomous systems are becoming increasingly crucial for the UK economy with far-reaching economic effects and the potential to bring significant opportunities for companies looking to reduce costs and/or improve efficiency.

Automation gap

Comparing the estimated levels of automation (by mid to late 2030s), given current adoption trends, and possible automation rates across highlighted sectors, the analysis points to a significant gap between estimated future automation trends and potential automation.

There are several reasons why UK PLC has been slow in the uptake of robotics. Many businesses see robots as expensive industrial machines for large installations on new production lines. Many also assume that robots require a high level of expertise to manage and operate.

The fact is, the ongoing development of robotic hardware and software has created a much more comprehensive range of solutions, including the introduction of systems designed to work safely alongside a workforce. Collaborate robots (cobots) are flexible robotic systems that can work safely in an environment with people. They are also much more flexible and can be re-programmed with intuitive interfaces and re-deployed depending on a company’s changing needs.

We have seen collaborative robots being used, not just in industry and production lines, but also in hospitality for serving food and mixing drinks, for camera work by the film industry and development tools for process and material research.

As the UK distributor for Techman Robots, we find ourselves having many open and honest conversations with companies looking to integrate robot technology into their business.

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Having worked closely with HMK, distributing Techman cobots for the past three years, LG Motion is positive that its complete understanding of motion technology will help offer the expertise, knowledge, and service to implement any company’s automation and development plans.

Established in 2004, LG Motion offers electromechanical motion systems for science and industry from its facilities in Basingstoke, Hampshire. LG Motion’s reputation is built on being a reliable and trusted development and manufacturing partner, adding value to projects across a wide range of industries.

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LG Motion is able to provide motion technology solutions for a very wide range of applications and industries. The company designs, engineers and supplies a broad range of electro-mechanical motion control systems and has a wealth of experience and knowledge, as well as design expertise to advise customers on the optimal approach to integrating motion technology for safe, effective production.

LG Motion offers a wide range of robots. For regular payloads, it offers the TM5 series, alongside the TM12 and TM14 for medium/heavy payloads. There is also TM12 and TM14) as well as a mobile series (the TM5M series) for added versatility. Each robot has features designed to enhance efficiency, including a built-in vision system, image detection, image enhancement and barcode identification.

In addition, the flow-based robot editing software ensures operators can complete any industrial program using intuitive click and drag user controls.

The cobots have the capability to interface with a variety of communications protocols to connect to a selection of industrial networks, as required.

Visit LG Motion at EDS on Stand C75. This year, the Engineering Design Show (12-13 October 2022 at the Coventry Building Society Arena) celebrates 10 years as the UK’s biggest event dedicated to engineering, electronics and embedded design.

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Collaborative robots (cobots) are efficient, cost-effective additions to a production line, and Techman collaborative robots from LG Motion are easy to implement and update to maximise effectiveness.

LG Motion offers a wide range of robots to meet regular payloads (the TM5 series), medium/heavy payloads (the TM12 and TM14) as well as a mobile series (the TM5M series) for added efficiency.

Each has a built-in vision system, image detection, image enhancement and barcode identification. The flow-based robot editing software ensures operators can complete any industrial program via click and drag user controls. The cobots interface with a variety of communications protocols to connect to a selection of industrial networks, as required.

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In more recent years, new ways of thinking have gained traction; rather than make their human counterparts redundant, the manufacturing robots of the future will work collaboratively alongside them. This future can be witnessed with the introduction of collaborative robots, commonly known as ‘cobots’, robots invented to complement human workers, operating in almost any environment. While we excel at complex thinking and problem-solving, robots are proficient at bringing accuracy to repetitive, and sometime unsafe, time-sensitive tasks.

What if robots do all the heavy-lifting and monotonous error-prone tasks, and employees are able to focus on more challenging and meaningful work. What if production lines were able to flow unsupervised with minimal error? The workforce of the future sees robots working collaboratively with employees and complement their work, improve efficiency and increase productivity.

Small, lightweight, and designed to operate safely for close human operation, cobots are an ideal entry point for many businesses looking to embrace robotics. Cobots can execute tasks with minimal programming and can be adapted to integrate into existing processes. Cobots are a world away from their industrial robot counterparts and well suited to SMEs. Around the world these collaborative robots are widely integrated and viewed simply as tools that coexist alongside human employees – allowing them to be more efficient.

Cobots are increasingly attractive to manufacturers who require flexible solutions for their production lines but may not have the capital needed to justify large investments in automation systems.

A recent study by Massachusetts Institute of Technology (MIT) found that cooperation reduced human idle time by 85%, making cobot-human working more productive than purely human or robot teams.

In the UK, cobots are completing all manner of tasks from stacking crates, painting and welding to sticking on car door liners and basic QA inspections.

The cobots’ lower cost and easy programming enables more businesses to implement them into their production processes. With their refined torque-sensing capabilities and lightweight but still solid construction, they are safer to use and easy to deploy. The ability to adapt their software to suit means they can quickly be redeployed to add flexibility to your operations.

Going forward, what will this look like? According to a report by the International Federation of Robotics (IFR), international sales for robots reached almost £10 billion last year, and has been increasing since 2017. The IFR predicts “a strong sales increase” in the coming years, particularly of robotic systems used for logistics, which is expected to more than double by 2022.

Future automation across all areas of manufacturing is inevitable, however with increasing development of cobots, there is no danger in them taking over completely as they need human intervention for connectivity and programming, for example, to carry out their purpose. Obviously, in the future there’s no doubt that many tasks that we do today will be taken over by cobots, but for an industry that suffers from skills shortages like manufacturing and the ongoing rise in UK wages, this may be a positive move. Using cobots provides many companies with an opportunity to upskill their employees, alleviating the dependency these skill shortages have caused.

This collaborative future has the potential for new, historically unimaginable, benefits. Rather than merely streamlining how businesses currently manufacture, it allows cobots to serve as a workhorse across organisations, transforming how businesses work and how they go about it.

There is no doubt that there are huge benefits of having an automated system for repetitive tasks, but we’re also advising our customers to take it slowly and asking the question, is your business actually ready for a cobot?

The core of our business is experience, knowledge and a pragmatic approach to providing motion technology solutions for a very diverse range of applications. Our solutions offer cost-effective collaborative robot solutions for industries that are easy to implement and update, our cobots are packed with features to maximise the effectiveness of your processes.

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