In-Line Test Systems for Production

In-Line Test Systems

Inline test systems play a vital role in ensuring product integrity at the most critical stage—just before shipment. By validating functionality directly on the production line, these systems detect faults early, reduce recall risks, and guarantee compliance with performance standards. Designed for speed and precision, they help manufacturers maintain quality without slowing down operations.

Ensure the Highest Quality All Down the Line

Let us help you speed up time to market while protecting your brand. At Averna, we know your production line is only as reliable as the tests behind it. Our inline production test solutions are built to keep pace with your output, ensuring every unit meets spec without slowing you down. By combining real-time data capture, vision inspection and automation, we help you maintain quality and reduce costly rework.

End-to-End Expertise, Built into Every Test Cell

Our test engineering experts don’t just add test and inspection to your line, we engineer it into the fabric of your production. Our inline production test systems are purpose-built to meet the demands of modern manufacturing: faster cycles, tighter specs, and zero-defect expectations.

Every solution we deliver reflects decades of hands-on experience. Our industry know-how and in-depth understanding of what it takes to test on a large scale means you're dealing with market experts.

Extensive Industry Expertise

Our in-line solutions cover a wide range of complex electronic, industrial and consumer products such as PCBAs, injection-molded parts, batteries, food, medical packaging and printers.

Thanks to years of cross-sector experience, we understand the nuances of diverse materials and regulatory standards. Whether you’re operating in high-precision electronics or high-throughput consumer goods, we adapt testing protocols to match your exact industry requirements.
Fully Integrated Test Cells

Tap into our test, measurement and integration expertise to develop and integrate a highly efficient quality-control solution for your line and speed up production.

Our modular systems are engineered for flexibility—from standalone stations to fully embedded solutions. We work alongside your engineering and operations teams to ensure minimal disruption.
High Speed Verification

We offer automated and semi-automated in-line test systems with high-precision vision inspection and surface inspection to rapidly identify and eliminate flawed products.

Powered by advanced image recognition, sensor data, and AI-driven analytics, our test systems detect micro-defects and deviations in milliseconds—well before they impact your bottom line or brand integrity.

Completely Integrated Production Testing

This is where our integrated test, measurement, vision and automation expertise come together for impressive benefits. Sample customer projects include:

A 10-camera system that inspects and verifies products moving at 120–140 meters per minute
An advanced PCBA tester that performs multiple LED tests and measures voltage up to 120 channels
A semi-automated in-line system that verifies truck dashboard assemblies to ensure zero defects
A consumer product operation featuring simultaneous precision assembly (gluing) and in-line testing
A 24-camera setup for a Tier 1 automotive supplier to verify perfect ABS/brake calipers

In-Line Test Equipment for your Production Line

With an Averna in-line test systems, clients boost production/yields, catch defects invisible to the human eye, reduce equipment downtime, and ensure repeatable results. Partnering with Averna lets you tap into the accumulated know-how and best practices from 5000+ test & quality projects.

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Our In-Line Testing Capabilities

PCBAs: Multi-channel and LED measurements (presence + color) and high voltage testing (3kV AC)
Flexible product adapters for handling different shapes and sizes of UUTs/DUTs and for quick changeovers
High-precision 2D and 3D cameras, including infrared, plus laser scanning (for example: defects detected at 1/100th of a millimeter)
Can include robotics, motion, precision assembly and packaging components
Are custom designed to accommodate high-volume and/or high-complexity
Touch-screen monitors and alerts for operators
Extensive industry, product and integration expertise built-in

Key Benefits

Fully automated, in-line vision inspection harmonizes quality systems and improves results
Integrates seamlessly into production environments without slowing down operations
Identifies surface defects as well as flaws not visible to human operators
Eliminates numerous time-consuming calibration and manual procedures
Results are never subjective to operator on duty for improved consistency
Improved efficiency typically allows clients to expand production capacity

Cover - Total Performance In-Line Validation for Electric Vehicle Motors

In the automotive industry, a leading EV technology pioneer partnered with Averna to implement a fully automated in-line validation system for electric motor subsystems. The objective was to ensure reliable performance and quality across the entire assembly process while eliminating manual testing and variability.

Multi-stage in-line validation combining HV, vibration and performance testing across motor and assembled subsystem
Fully automated test sequence integrating robotic handling, PLC-controlled synchronization and real-time measurement via UDS

By embedding validation at each stage of assembly, this approach ensures consistent quality, reduces rework and enables high-throughput production while maintaining strict performance requirements for EV powertrain systems.

45 min → 5 min test time per unit

90 kW test power

14k RPM / 166 Nm Up to

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Related Resources

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Averna's Universal In-Line Test Platform

UniLine's flexible design allows you to automate all functional, safety, ICT, and EOL tests as well as part labeling and programming operations for partial or final PCB assemblies.

Ready to Learn More about In-Line Production Testing?

Let’s talk about your line, your challenges, and how we can build the right test solution around them. Whether you’re scaling up or solving a persistent QA issue — our experts are here to help you move forward with confidence.