An electronics manufacturer producing PCBs for automotive braking systems encountered challenges in their quality control process. These PCBs contained fragile electronic chips that required careful handling. When dropped, these PCBs needed additional testing to ensure safety and functionality, significantly impacting production efficiency.
The standard procedure required operators to set aside dropped PCBs for additional testing before kit packaging. However, fearing penalties, operators often avoided reporting such incidents. The non-compliance rate reached 300 incidents per 10,000 units, creating serious quality and safety risks for these critical braking system components.
Assembly Copilot provided an automated solution to verify PCB handling throughout the assembly process. The software used computer vision and AI to detect when PCBs were dropped during handling. When the system detected a dropped PCB, it tracked that specific PCB to ensure it went through the required additional testing before proceeding.
The implementation was straightforward. Cameras were installed at key handling points to observe PCB movements during assembly. Assembly Copilot’s AI algorithms analyzed these movements to identify potential drops or mishandling of the components. This process-focused system ensured that any dropped PCBs received proper testing with approved quality standards.
Assembly Copilot significantly improved PCB handling compliance, slashing scrap rates by over 96%—dropping from 30% to under 1%. The automated monitoring system ensured proper testing protocols while fostering a more positive quality control environment. This improvement enhanced both product safety and operator confidence.
A leading electronics manufacturer prioritizes quality control and safety compliance in producing critical automotive components.
Automotive Electronics Manufacturing
Improve PCB handling compliance through automated monitoring and incident detection.
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