End-of-Line Testing as a Key Efficiency Driver

The demands on battery manufacturing processes are increasing steadily. OEMs and suppliers must meet the highest quality standards while ensuring efficiency and scalability. Faulty battery modules or packs can lead to costly recalls and reputational damage. Yet many testing processes remain inefficient, non-automated, or only partially scalable.

Three core challenges frequently arise on the shop floor:

• Defects are detected only at the end of production, leading to scrap and rework.
  
• Manual or outdated test methods slow down production and raise operating costs.
  
• Lack of flexibility in test systems hampers adaptation to new cell technologies and rising volumes.
  

The solution lies in optimized end-of-line testing that combines automation with scalable, future-ready processes.

h-kon’s Solution: Efficient End-of-Line Testing

Automation as a Driver of Efficiency

h-kon leverages state-of-the-art automation to reduce error rates and streamline throughput. Real-time defect detection improves quality control while cutting test durations. Advanced vision systems and machine learning algorithms identify defects early and ensure consistent inspection performance.

Predictive Maintenance for Maximum Uptime

Our systems integrate predictive maintenance to detect anomalies early and minimize downtime. By using sensor data and AI-driven analytics, maintenance is scheduled as needed—reducing costs and extending system lifespan. Real-time monitoring via sensors further optimizes service intervals.

Scalable Systems for Growing Demands

Tomorrow’s test systems must be adaptable. h-kon develops modular platforms that allow new battery formats and increased volumes to be integrated without costly redesigns. Cloud-based analytics enable ongoing optimization. Our modular setups can be reconfigured for new cell types with minimal effort.

Proven in Practice: A Case Study

Challenge

A leading European battery cell manufacturer faced rising production volumes. Their existing end-of-line system caused delays, high scrap rates, and lacked scalability.

h-kon’s Response

h-kon delivered an automated test system that combines visual inspection, electrical testing, and defect detection. High-resolution imaging spots even the smallest anomalies, while intelligent data management ensures full traceability. Predictive maintenance minimized unplanned downtime, and the modular architecture supported easy scaling to new cell formats.

Results

• 35% reduction in defect rates
  
• 40% faster testing per battery pack
  
• Scalable design compatible with future cell formats
  
• 25% reduction in unplanned downtime through optimized maintenance
  

Conclusion: Book a Potential Analysis and Unlock Actionable Insights

End-of-line testing is a critical lever for cost-efficient battery production. Companies that optimize early benefit from lower costs, higher quality, and future-proof scalability.

h-kon delivers tailored test stand technologies that boost quality and efficiency long-term. Leverage our expertise to future-proof your battery manufacturing.

Schedule a non-binding potential analysis today and discover your optimization opportunities.

Watch our EoL efficiency video: https://www.youtube.com/watch?v=7uCRTkLAzJA

Der Beitrag Maximizing Efficiency in Battery End-of-Line Testing: How OEMs and Suppliers Can Cut Time and Costs. erschien zuerst auf h-kon.

h-kon specialises in the development of assembly and testing technology processes for battery cells, modules and packs. It offers comprehensive solutions in plant construction, including commissioning, maintenance and service, and thus makes a significant contribution to the infrastructure of the energy and transport transition.
 
As part of this cooperation, ARTEC Engineering GmbH will act as a software service provider in automation technology for h-kon. The focus will be on programming PLC control software, robot applications and high-level language applications required for the development of end-of-line testing technologies.
 
The engineers at ARTEC Engineering GmbH rely on technologies such as C#/WPF for desktop applications as well as Angular, TypeScript and web services for web-based applications. Object-relational mappers (e.g. NHibernate) are used for database connections and XML/XSLT via XMPP or MQTT for the connection of third-party systems.
 
With its 11 employees, ARTEC Engineering GmbH ensures the commissioning and supports the preventive maintenance of h-kon's long-standing customers
 
ARTEC has already contributed to h-kon's success by developing a new, flexible user interface. This successful collaboration is now to be further intensified by the new partnership.
 
Roland Arnold, Managing Partner of h-kon, emphasises the need for strategic partnerships in view of current challenges such as procurement bottlenecks, price trends and a shortage of skilled workers: ‘We are in a rapidly growing market with the construction of battery testing technology systems. Strategic partnerships are therefore the logical way to secure and expand our market position.’
 
In return, ARTEC Engineering GmbH benefits from the Schulz Group's extensive network and can utilise numerous synergies in sales. In this way, h-kon is forging closer ties with one of its most important software suppliers and creating additional growth potential for both companies.
 
ARTEC Engineering GmbH has been successfully managed by Thomas Reiter and Bernd Hofmann since 2002, free of bank obligations and independent of external companies. The company serves markets such as electronics manufacturing, measurement and testing technology, laser lithography, chemical supply and special machine construction. The working methods of the successful engineering office and the close ties to employees and customers reflect the spirit of h-kon.
 
Tobias Reiter from ARTEC sees great opportunities in the partnership: ‘The cooperation with h-kon GmbH opens doors to new sales markets for us, across industries and worldwide.’

From left to right: Bernd Hofmann (Managing Director ARTEC Engineering GmbH), Roland Arnold (CEO h-kon GmbH), Thomas Reiter (Managing Director ARTEC Engineering GmbH).

Der Beitrag Strategic partnership: h-kon & ARTEC Engineering erschien zuerst auf h-kon.

Thanks to expertise from Ravensburg, the electrification of mobility in Germany is becoming more and more of a reality. System supplier and process developer h-kon is implementing a major order for end-of-line testing stand technology at a production facility of a US automotive supplier in Darmstadt. The testing is conducted on battery modules for public transport vehicles in a three-shift operation. The customer-specific end-of-line testing system was developed by h-kon and meets the highest process accuracy, stable automation processes, and availability. 
 
Founded in 2006 and based in Ravensburg, the company foresaw the boom in electromobility early on. Since 2018, h-kon has been planning and developing battery module assembly and battery pack assembly systems. Just one year later, the company also ventured into the design of end-of-line testing technology for battery modules and RCB testers. In this innovative and new business field, h-kon has established itself not only as a system supplier but also as a general contractor with the help of experienced partners in power electronics and manufacturing. 

 
h-kon on a growth trajectory

With success: After receiving the first order for end-of-line testing stands for a US production facility of the automotive supplier a few years ago, the equipment supplier was already involved in a new order for plant expansion at the end of 2021. The order for the Darmstadt production facility now marks another major order for end-of-line testing stand technology. 
 
In light of this, the Ravensburg-based company expects a significant increase in performance for the current fiscal year. Specifically, h-kon anticipates an increase of approximately 60 percent in performance compared to the previous year's value. In 2021, the total performance amounted to 3.8 million euros. 
 
"The outlook is extremely promising," says Roland Arnold, Managing Partner of h-kon GmbH, and adds, "Due to the rapid growth, we will also adapt our number of employees to the new requirements and are looking for experts to complement our development teams." Currently, around 15 employees work for h-kon. The majority-owned system supplier is part of the Schulz Group, a technologically oriented corporate group that h-kon can additionally rely on for extensive expertise in robotics and digital factory planning.

Der Beitrag End-of-line test technology for US automotive supplier. erschien zuerst auf h-kon.