Case Study 01 · Instrument Cluster Assembly & Test Line · Image: 1200×340px
Case Study 01 · AT BUILD-L · EV & Automotive

Instrument Cluster Assembly & Test Line

Tier-2 Automotive Supplier, Aurangabad
The Challenge

Semi-automatic assembly and 100% functional test line for 2-wheeler instrument clusters — 3 product variants, 800 units per shift. Required: display illumination, pointer sweep, CAN bus, button function, and IP54 seal verification. Previous supplier failed to deliver the CAN test capability.

Our Solution

6-station AT BUILD-L assembly and test line. Machine vision display test, AT DAQ-S CAN communication test (Vector CANalyser interface), air-decay seal test. Variant selection by barcode scan at entry — no manual recipe changes.

Results
All 3 variants on single line — zero changeover tooling
100% test coverage on all specified parameters
Cpk >1.67 on all critical measurements
PPAP approved on first submission
870 units/shift — 9% above target
Case Study 02 · EV Charger Assembly Line · Image: 1200×340px
Case Study 02 · AT BUILD L · EV & Automotive

EV Charger Assembly Line — 3.3kW AC Slow Charger

EV Charger Manufacturer, Bengaluru
The Challenge

Scale from 200 units/day (manual assembly) to 1,000 units/day within 12 weeks. Required poka-yoke assembly with 100% AT 1000 / AT DAQ-S functional EOL test integrated for IEC 61851 compliance.

Our Solution

7-station AT BUILD-L semi-automatic assembly: PCB loading, torque-controlled fastening with data logging, connector presence verification, force-controlled cover closure, AT DAQ-S EOL test (voltage, current, efficiency, OCPP), laser labelling, and packing.

Results
1,150 units/8-hour shift (target: 1,000)
Delivered in 10 weeks from BOM freeze
Defect escape at EOL: <0.05%
Customer ordered 2nd line for new facility
Line is export compliance benchmark
Case Study 03 · Telematics Unit EOL Test System · Image: 1200×340px
Case Study 03 · AT DAQ-S · Telecom & Communications

Telematics Unit EOL Test System

Vehicle Telematics Manufacturer, Pune
The Challenge

100% production test covering GPS, 4G/LTE, Bluetooth, Wi-Fi, CAN bus, and power management within a 90-second cycle. Previous approach used 3 separate stations causing test escapes and low throughput.

Our Solution

AT 1000 single-station EOL system with AT DAQ-S and purpose-built DUT fixture. All 6 test categories run sequentially: GPS (NMEA validation), cellular (AT command ping), Bluetooth/Wi-Fi (RF), CAN (message broadcast/receive), and power management.

Results
Cycle time: 88 seconds (target: 90 met)
6 test categories in 1 station — no transfer
Test escape rate: zero in first 3 months
310 units per 8-hour shift
Customer expanded to 3 identical systems

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