Customer Case

A key player in China’s automotive smart cockpit industry, specializing in the R&D, production, and delivery of Cockpit Domain Controllers (DCUs) needed urgent help automating a system that was highly reliant on manual labor. 

The company operates at large-scale mass production capacity, with established partnerships with top-tier automakers and a reputation as an industry benchmark. As business scaled and market demands increased, manual testing bottlenecks began to hinder development. 

The company’s existing test operations were driving high costs, volatile production capacity, and inconsistent quality. Individual testing stages were fragmented and untraceable, with no unified data trail across operations. GP12 processes were slow and inefficient, and the line lacked the flexibility to accommodate multiple product models without significant disruption. 

With top automakers demanding tighter quality standards and production volumes continuing to grow, the company needed to replace manual testing with a stable, fully automated alternative.

The solution: A purpose-built answer to a complex problem

Provectron designed and deployed a customized Cockpit DCU Automated Test Line, integrating self-developed software and AI algorithms, robotic loading and unloading, full MES integration, and fully automatic GP12 processing. 

The line delivers end-to-end test coverage across the full production flow, with all results automatically synced to the MES for real-time traceability. Robotic handling minimizes manual intervention, while Provectron's self-developed software and AI algorithms support product iterations and multi-model compatibility. Fully automated GP12 processing, a specific pain point for the customer, was a key capability delivered by the solution.

The implementation: A structured path to mass production

Provectron managed the complete project lifecycle: in-depth demand research, customized design, core technology development, on-site installation and commissioning, and pilot production optimization, through to a smooth transition from manual to automated testing.

The Results: A production line that delivers on every metric

Labor costs were reduced by 60–70%, with a production cycle of 60 seconds per unit, First Pass Yield exceeding 99.5%, and OEE above 85%. The project delivered a complete automation upgrade with full-process traceability, resolving the core pain points that had constrained the customer's growth. 

The new line also introduced offline testing capability, reducing downtime risks and ensuring uninterrupted production. Self-developed software and algorithms provide ongoing adaptability as products evolve, while multi-model compatibility gives the customer room to scale.

Provectron's perspective:

DCU manufacturers are under real pressure right now, their customers expect automotive-grade quality and zero tolerance for testing gaps, while their own operations are still catching up with the scale of demand. What we built here wasn’t only a faster line, it was a complete rethink of how testing should work at mass production volumes, with full traceability and the flexibility to grow with the business.