Automation of PCBA Testing at BTL Medical Technologies s.r.o.

From challenge to solution: BTL case study

BTL Medical Technologies s.r.o. is one of Europe’s leading manufacturers of medical equipment, operating globally in over 70 countries. Since its founding in 1993, BTL has grown from a small engineering firm to a key producer of technologies for physical therapy, cardiology, and aesthetic medicine. Today, it employs over 2,800 people, including more than 400 development engineers.

The in-house production and testing of approximately 400,000 printed circuit boards (PCBs) per year takes place in one of BTL’s PCB manufacturing facilities in Benešov near Prague. This process is critical, with a direct impact on the quality and reliability of the final products. The High-Mix, Low-Volume production mode—with frequent changes of PCBA types and smaller batches—requires exceptional flexibility and efficiency. At the same time, the company faces a shortage of technically educated staff for PCBA testing, which increases the risk of human error and limits the scalability of the process. That is why BTL decided to implement the Test-it-off platform from KINALI, which automates PCBA quality control, minimizes dependence on manual operation, and brings a significant improvement in efficiency and adaptability of the entire testing process.

Project requirements

BTL’s management was looking for a solution that would:

• reduce dependency on manual PCBA inspection,
• ensure stable and uninterrupted operation without the need for supervision,
• quickly integrate new products in High-Mix, Low-Volume production mode,
• address the shortage of qualified operators for testing stations,
• seamlessly integrate with existing testing infrastructure (ICT and FCT testers, MES system)

The aim was not only to streamline testing, but also to strengthen production’s readiness for further growth and changing market requirements.

Solutions and implementation

The Test-it-off solution was designed as a fully autonomous workstation that adapts to high variability in production. In collaboration with BTL’s technical team, it was deployed and tailored to specific operating conditions. The main features and steps of the implementation included:

• Optimization for High-Mix, Low-Volume production: Changeovers between PCB types in under 10 minutes, and introduction of a completely new type in under 60 minutes.
• No-code NPI: Quick and easy introduction of new products without programming. Operators can master the system without formal training.
• Intuitive interface and easy operation: A clear user interface and modular design make setup and use straightforward across diverse projects.
• Live monitoring and batch completion prediction: Real-time tracking of test progress with estimated completion times for improved production planning.
• Universal testing platform: One workstation handles multiple PCBA types. At BTL, it was configured for unsorted PCBs in KLT boxes, but also supports conveyors, trays, or CAB magazines.
• ICT/FCT test automation: Full integration with leading testers, including automatically closing fixtures.
• Unattended operation and alerts: The system runs independently and notifies operators only when assistance is needed, ideal for highly autonomous operation.
• Staging of fixtures on trolleys: Accelerates changeovers and reduces downtime during production switches.
• Speed optimization of system operation: Custom 3-axis PCBPlacer ensures precise placement and faster cycles. Dual-fixture handling and optimized AUBO robot trajectories minimize idle time and boost efficiency.
• Primary hardware – AUBO collaborative robot: Proven solution with 18 months’ warranty and easy maintenance. Recipient of the 2024 “Čapek Prize.”

Technical parameters

Conclusion

The Test-it-off solution enabled BTL to respond flexibly to operator shortages and increasing pressure on stable production quality. Its key advantage was the simple, intuitive operation of the Test-it-off workstation, which allowed staff to master the system quickly without prior training and to begin normal operation almost immediately. The customer was able to introduce new products (NPI) into the Test-it-off system by themselves in under one hour, with no need for programming or deep technical expertise.

In recognition of its contribution to modernizing industrial testing, the Test-it-off solution won the Visionary 2022 award and helped KINALI earn a place among the top three system integrators in the Czech Republic in the Industry 4.0 Awards 2024. The awards confirm what real-world use has already proven: Test-it-off is an innovative, flexible, and proven solution designed for next-generation automated manufacturing.

Find out more at www.testitoff.eu.