ESCATEC enables mass production of complex smart utility meters for leading OEM

The OEM required a manufacturing partner capable of delivering both high volumes and high complexity, without compromising on quality.

While setting up assembly lines and testers for ramp-up was straightforward thanks to a strong partnership, several operational challenges emerged on the production side:

• High product complexity: The mechanical structure inside involves multiple precision components, requiring accurate stacking and alignment.

• Labour-intensive assembly: The assembly of intricate gear stacks requires highly trained operators with significant muscle memory. New operators typically need over two weeks of hands-on experience to meet cycle times.

• Delicate component handling: Sensitive parts such as light pipes require careful handling to avoid damage or scratches.

• Quality risks in manual processes: Manual screwing, printing and testing can introduce inconsistencies in output – with hundreds of thousands of units per month at stake.

To overcome these challenges and prepare for full industrialisation, ESCATEC introduced a series of automation initiatives along the production line.

Precision automation in printing

The customer’s hot-stamping process – printing a white background on a black part – was sensitive to defects such as incomplete coverage or dot marks due to uneven moulding surfaces. ESCATEC implemented:

• A 2-in-1 automatic stamping machine to improve consistency and quality

• Future upgrades: automated cleaning and optical inspection to further reduce human error and increase process control

Intelligent screwing with torque monitoring

Manual screwing was replaced with an automated screwing system featuring real-time torque control:

• Each screw is tightened to exact torque specifications

• Screws outside tolerance are automatically rejected

• Significantly reduces risks of overtightening, thread damage or loose parts

Robotic testing and traceability

ESCATEC added an automated robot arm for the test process, replacing manual loading/unloading and integrating directly with the MES system:

• Real-time pass/fail results sent automatically

• Eliminates manual barcode scanning and improves traceability

Looking ahead: laser marking and full-line automation

To further improve efficiency and traceability, ESCATEC is now developing a laser marking system to replace serial number label pasting. This future upgrade supports:

• Cleaner design, fewer components

• Improved traceability and durability of product IDs

• Full MES integration

The long-term goal is a fully automated line for the customer’s highest-volume product line, reducing manual steps and ensuring consistent high-quality output.

• Scalable mass production: Hundreds of thousands of units are assembled, tested, packaged and shipped monthly around the world across several product variants.

• Improved consistency and yield: Automation led to reduced defect rates in printing, assembly and testing

• Faster operator ramp-up: Critical processes still requiring manual work are now better supported with clear instructions and training plans

• Ready for the future: Automation infrastructure supports traceability, MES integration and continuous process improvement