Optical and physical tests

Depending on the testing task, additional procedures can be integrated directly into the inline process. Optical inspections Leak tests Load tests Partial identification and barcode recognition

Programming and process integration

In addition to the actual testing, production-related process steps can be carried out and documented automatically within the inline system. Programming and flash processes Assembly processes Label printing PASS/FAIL sorting Handover to subsequent process steps

Integrated Test Systems

Inline Systems

INLINE TEST SYSTEMS

Inline systems from MCD Elektronik integrate testing and automation stations directly into existing production lines, thereby increasing efficiency, cycle time, and process reliability. Whether for PCB testing, EOL testing, or assembly lines: MCD develops custom inline solutions that are precisely tailored to the product, manufacturing environment, testing requirements, and level of automation—featuring conveyor technology, intelligent barcode recognition, and automated handling.

INLINE TESTS

Inline tests are automated quality controls that are directly integrated into the production process. The test specimen is contacted, stimulated, measured and evaluated within the line without being separately transported to an external testing location.

Inline Systems

Integrated Test Systems

Integrated testing solutions for the ongoing production process

Inline test systems connect the testing process directly with material flow, cycle time, handling, process control and data management. This means that errors can be identified at an early stage, test results can be documented directly and faulty parts can be specifically rejected.

The close integration into production supports reproducible quality, reduces manual interventions and creates the basis for complete traceability.

Quality control

100 percent testing in series production

Process integration

directly in the ongoing production flow

Traceability

Complete documentation of the test results

TYPICAL TESTING METHODS AND APPROACHES

Inline test systems connect testing and process steps directly with the production flow. Depending on the application, functional tests, circuit board tests, electrical measurements, communication tests, optical inspections as well as programming and documentation processes can be integrated.

Testing of Electrical Assemblies

Close-Up View

Inline Test System

Barcode Scanning in the Inline Test System

Detailed View of the Inline Test

Component Identification and Traceability

Electronic assemblies are tested within the line under defined conditions and relevant electrical and functional measurements are automatically evaluated.

Functional tests of electronic assemblies
Board checks
Current and voltage measurements
Signal and communication tests

Depending on the testing task, additional procedures can be integrated directly into the inline process.

Optical inspections
Leak tests
Load tests
Partial identification and barcode recognition

In addition to the actual testing, production-related process steps can be carried out and documented automatically within the inline system.

Programming and flash processes
Assembly processes
Label printing
PASS/FAIL sorting
Handover to subsequent process steps

Measurement and process data can be transferred directly to higher-level systems and used for traceability within series production.

Digital result documentation
Database connection
MES connection
ERP connection

Flexible inline concepts for different production processes

Inline test systems can be designed as linked test stations, fully automatic test lines, rotary transfer or transport systems, robot-supported cells or integrated assembly and testing systems.

Test Methods and Approaches Used

In-line test systems are integrated directly into the ongoing production flow. The entire sequence—from the test specimen’s entry through contact, measurement, evaluation, and documentation to further processing within the line—is viewed as a single, continuous process.

Functional and Electrical Tests

Functional Testing of Electronic Assemblies

Circuit Board Testing

Current and Voltage Measurements

Signal and Communication Tests

Visual and Physical Inspections

Visual Inspections

Leak Tests

Stress Tests

Barcode Recognition and Part Identification

Production-Oriented Process Integration

Programming and Flash Processes

Assembly Processes

Label Printing

PASS/FAIL Sorting

Line and Data Integration

Interlinked Test Stations

Rotary Transfer and Conveyor Systems

Robot-Assisted Cells

Database, MES, and ERP Integration

FREQUENTLY ASKED QUESTIONS

FAQS

An inline test is a testing procedure that takes place directly within a running production line. The test item is automatically transported, identified, contacted, tested, and evaluated without unnecessarily interrupting the production flow. This allows function, quality, and process data to be monitored and documented directly during mass production. Inline testing is particularly well-suited for automated manufacturing with high production volumes, short cycle times, and requirements for complete traceability.

In-line test systems are suitable for electronic, electromechanical, and mechatronic products. These include printed circuit boards, control units, infotainment components, communication modules, sensors, actuators, industrial electronics assemblies, and mass-produced products with high testing and documentation requirements. Furthermore, inline testing is well-suited for the product validation of components that are typically manufactured on a production line.

Typical tasks include functional tests, end-of-line inspections, current and voltage measurements, signal and communication tests, optical inspections, leak tests, flash and programming processes, barcode recognition, labeling, sorting, and database and ERP integration.

An inline test system is useful when high production volumes, short cycle times, repetitive test sequences, automated handling, or complete traceability are required. It is particularly useful when testing, assembly, identification, and process data need to be integrated into a continuous manufacturing process.

Traceability ensures that every test result can be uniquely linked to a product, a serial number, or a barcode. This makes quality data traceable, allows the causes of errors to be identified more quickly, and enables production processes to be evaluated more effectively over the long term.