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How Datalink Electronics Enhanced Production Testing with Smart Automation and Software Integration — Improving Quality, Efficiency, and Reliability
Client Profile / Background
A major manufacturer of mobile lifting and transport platforms partnered with Datalink Electronics to develop a custom automated test system for their electronic control assemblies.
The collaboration builds on a long-standing 14-year partnership , during which Datalink has supported the client with design, manufacturing, and electronic test solutions across multiple product generations.
Working in demanding industrial environments, the client sought to improve testing accuracy, speed, and consistency, while reducing manual handling and labour requirements.
Datalink provided the complete electronic and software integration , while the client supplied the mechanical rig and framework.
As production volumes grew, the existing test approach — based on manual and semi-automated methods — became a bottleneck.
The client experienced recurring issues such as:
- Difficulty distinguishing between true electronic faults and calibration drift, resulting in “no fault found” investigations.
- Inconsistent testing outcomes across different operators and shifts.
- High labour involvement in repetitive test processes.
- Limited traceability and data capture for ongoing quality improvement.
The challenge was to create a reliable, automated testing solution that could identify real issues accurately, improve throughput, and provide consistent, verifiable results.
Datalink designed and delivered a bespoke automated test platform , combining custom control electronics, embedded firmware, and intelligent software .
Key Features and Differentiators:
- Automated Diagnostics: The system can reliably identify real failures, calibration errors, or general issues without operator intervention.
- Integrated Software Interface: User-friendly test software delivers consistent pass/fail results and records full test histories for each unit.
- Rugged Electronics: Designed to perform accurately under challenging industrial conditions, maintaining reliability over extended production cycles.
- Scalable Architecture: The platform accommodates future product variants with simple software updates and modular electronics.
The result is a repeatable, data-driven testing process that ensures quality assurance while reducing manual input.
- Collaborative Design:
Datalink’s engineers worked alongside the client’s mechanical team to define specifications, diagnostic parameters, and data requirements. - Prototype & Validation:
A pilot system was deployed on one production line for performance evaluation and fine-tuning. - Optimisation:
Software algorithms were refined to improve fault recognition and reduce calibration drift misreads. - Full Deployment:
The system was rolled out across multiple production areas, with full operator training and technical documentation. - Ongoing Partnership:
Datalink continues to provide technical updates and support , ensuring the solution evolves alongside new product designs.
The Results / Outcomes
Measured Improvements:
- Significantly faster testing cycles with consistent, reliable results.
- Reduced manual handling and technician input , freeing teams to focus on higher-value tasks.
- Improved on-line quality and first-time pass rates due to more accurate diagnostics.
- Notable reduction in “no fault found” returns , cutting unnecessary rework and aftersales costs.
Partnership Benefits:
- Strengthened the client’s confidence in production quality and test data integrity.
- Reinforced a trusted engineering partnership built over 14 years of collaboration.
- Supported ongoing ISO 9001 compliance and continuous improvement initiatives.
