Who is TNO?

TNO, the Netherlands Organisation for Applied Scientific Research, is a leading independent research institute that bridges the gap between science and industry by translating advanced research into practical, scalable solutions, with a strong focus on Industry 4.0 technologies such as smart manufacturing, digitalisation, AI-driven production systems and connected factories, helping companies and governments accelerate innovation, improve competitiveness and bring validated, future-ready technologies to market.

The Challenge

Electronics repair teams face increasing complexity every year. New device models are introduced continuously, and repair procedures vary depending on the fault and the specific product variant.

TNO wanted to research a "no fault forward" approach that would:

Maintain consistent repair quality while improving efficiency
Scale to an ever-expanding range of device models
Handle workflows where repair steps vary by fault
Reduce errors caused by the steep learning curve for technicians

The Solution

Variant-Specific Repair Instructions Powered by AR & Verification

Together, TNO and Ansomat created a repair workflow that automatically loads the correct instructions for each device and guides the technician through fault-dependent steps—while verifying completion along the way.

Variant-aware, skill-based guidance for any technician.

The solution is organised across 4 workcells covering the full repair flow.
Disassembly & Component Identification: products are taken apart and components are identified and sorted.
Inspection & Assessment: parts are tested to verify functionality and detect defective components.
Remanufacturing & Reassembly: components are repaired and the product is rebuilt.
End-of-Line Test: final validation before release.
The setup is designed for high-mix, low-volume operations.
3 manual workcells operate with digital work instructions.
2 stations use Machine Vision cameras for automated visual verification.
1 station includes a controlled screw-driving tool to ensure correct fastening.

How It Works

Scan Barcode to Load the Right Variant and Workflow
A barcode scan identifies the correct device variant and immediately triggers the appropriate repair flow.

Analyse the Pack and Display Corrective Actions
The system supports diagnosis by identifying issues and showing the relevant corrective actions for that specific fault.

Projector-Guided Picking from the Correct Bin
Technicians are guided visually to select the right items from the correct bin using projector-based instructions—reducing mix-ups and wasted time.

Vision Confirmation of Completed Actions
A vision system confirms key steps have been completed, reducing the risk of skipped actions.

Cross-Station Data Checks to Catch Incomplete Work
Repair data is carried forward from previous stations to detect unfinished or incorrectly completed steps before the pack moves on.

Label Printing for End-to-End Tracking
A correct, traceable label is printed with identifying information so each repaired pack can be tracked through the process.

The Impact

By introducing variant-aware repair guidance and verification, TNO and Ansomat reduced complexity on the shop floor and made repair outcomes more predictable. Technicians could ramp up faster, and the system helped prevent common errors before they became costly rework or returns.

Why It Matters

When repair steps change based on both device variant and fault type, traditional documentation breaks down. Digital, variant-specific work instructions ensure the right process is followed every time, regardless of technician experience, while building traceability into the workflow.