How IoT in Quality Control Is Supporting Hardware Production

IoT hardware quality control is the difference between a functional product and a field failure. And yet, while most teams focus on visual defect detection and factory acceptance testing, they often ignore the firmware and cloud levels of QC — two layers just as critical.

Challenges to expect in the way? Testing data is frequently scattered or incomplete. Outsourced assembly makes it hard to enforce consistent standards. And too often, teams don’t catch issues until after the devices are in customers’ hands.

Luckily, WebbyLab tackles that. We help you fill QC gaps early by fitting into your RACI matrix at any stage — from defining test plans and creating firmware quality control modes to managing cloud-based QC data and providing IoT consulting. In this post, we’ll discuss how that works.

We make the test scenario as simple and fast as possible for testing all components. For example, our QC mode test scenario for the A/C drain line cleaner includes seven simple steps — and that covers everything we need.

Kostiantyn Oliynyk

Head of IoT at Webbylab

Updating firmware in A/C drain line cleaners

Highlights:

• Quality control is more than factory tests — it must also cover your firmware and cloud systems to catch issues that surface only after deployment.
• Firmware QC modes let you test every component (such as sensors, LEDs, buttons, or Wi-Fi) right on your device.
• Need to detect defects early and analyze trends? Never skip cloud-based QC data management and analysis.

The Role of an IoT Vendor in Your Device Production Lifecycle

You might assume that once your hardware is in the hands of a large manufacturer, quality control is all taken care of. And yes, most factories do have their own hardware diagnostics and QC processes, along with accounting and tracking systems. But there’s a critical layer that often goes under-supported: firmware installation and testing.

At WebbyLab, we integrate into your product lifecycle precisely at those points where traditional manufacturing support drops off. For projects where we develop the firmware, we often participate directly in setting up QC steps during production, whether that’s through hands-on consulting or embedding device testing mechanics into the firmware itself.

Things get even more interesting when your final device isn’t assembled at the factory, but at your own or a partner’s production site. In these cases, you’re likely integrating multiple components, and the fully assembled device must undergo final quality control. That’s precisely where we help.

Besides the production-level QC, we also assist in:

• Firmware QC mode design
• Cloud-based QC data pipelines
• Automated test rigs/devices and diagnostic tools

Some of our projects, such as MyBox, Intellect, and Propuskator, received this kind of QC support, which made sure their teams had consistent, scalable testing strategies in place.

The MyBox charging station

When we’re brought into a production flow, we verify functionality at every layer. Whether it’s a test script running on a microcontroller or a cloud dashboard showing pass/fail rates across batches, it’s all about reducing defects and increasing production yield.

Kostiantyn Oliynyk

Head of IoT at Webbylab

Firmware-Embedded QC Modes

A firmware QC mode is a specific mode that runs a predefined set of tests to verify that everything — from sensors to buttons — works correctly.

When we’re developing IoT device firmware, we build in these QC procedures from the outset. This allows for fast, automated testing of every critical component, including PCB inspection, sensor calibration, connectivity module checks, and more.

The results of this IoT quality assurance are then sent to the cloud, where they can be tracked and analyzed. This works in parallel with traditional manufacturing standards but gives you better visibility and control.

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A/C Drain Line Cleaner by WebbyLab: QC Mode Steps

The QC mode testing scenario for the smart automated A/C drain line cleaner we worked on includes:

• Switching to QC mode via a physical button
• Testing all LEDs
• Wi-Fi connectivity check
• Cartridge presence sensor test
• Reset button test
• Flood sensor test
• Valve dispensing test

With just seven simple steps, we cover all critical sensor networks and peripherals and get a full functional snapshot of the device before it ships. Plus, the QC report is generated and sent to the cloud with the device’s unique ID.

Building these checks into firmware validation means less manual work, fewer mistakes, and faster production.

Kostiantyn Oliynyk

Head of IoT at Webbylab

Cloud-Based QC Data Management and Analytics

Cloud-based machine data management and quality analytics means your device’s test results are automatically sent and stored online, where they’re organized, easy to access, and ready for reporting.

WebbyLab’s IoT product development steps include building systems that collect QC reports directly from devices during production and send them to the cloud. We also ensure cloud integration with ERP or MES systems, if that’s what you’re currently using.

What Are the Different Types of Quality Control? [With Case Studies]

Depending on where you are in the lifecycle, how your product is assembled, and the level of component reliability you’re aiming for, your electronic quality control strategy may fall into:

• Automated QA for consistent, repeatable results
• Real-scenario stress testing for simulating device behavior under actual usage conditions
• Combination of automated, manual, and stress testing for more complex setups or higher-risk hardware

For typical scenarios and tests, especially for security testing, we selectively implement checks based on our test scenarios in real-world usage conditions. This includes testing in live production environments or within the Internet of Things for enterprises.

After the IoT in quality management testing cycles are complete, we provide a full list of tested devices with timestamps and progress accessible in a dedicated environment.

Let’s see what that looks like in practice.

MyBox: Automated QC for Assembled Devices

The MyBox charging station

For MyBox, we developed a custom QC toolkit that runs automatically after the device is fully assembled. A separate testing unit connects to the device, executes all predefined checks, and then sends the results directly to the cloud. This ensures that nothing ships without hardware verification — and no human has to babysit the process.

We also used car and connector emulators to simulate real-world conditions during firmware development. This gave us the ability to test load scenarios in office environments before field deployment. For projects like this, leveraging firmware development services can streamline the creation, testing, and optimization of embedded software, ensuring devices perform reliably under diverse real-world conditions.

Intellect: Stress Testing Smart LED Lamps

The Intellect mobile app and device

In our Intellect project, which involved developing firmware for smart LED lamps, we took a hybrid approach. We used a specialized programmer and debug tool during development for real-time monitoring and flashing of firmware.

After initial testing, we left the controller connected to a real lamp for a two-hour live stress test, gathering logs to identify edge-case bugs or hardware quirks that might not surface during quick tests.

Propuskator: Real-World Load Testing for Access Controllers

The Propuskator mobile app

Our Propuskator project involved access control system controllers. After manufacturing and firmware installation, we ran load and usage emulation scenarios that mirrored real-world use: door triggers, cloud sync, user tasks, and more. This type of testing validated not only the consumer IoT security devices themselves, but also their interaction with firmware and cloud infrastructure.

In case you need more guidance on how to apply layered QC in your own workflows, don’t miss our post on IoT testing best practices.

Last Thoughts

If you’re developing your own hardware, applying IoT for enhanced quality control is a must. It keeps your product reliable, customers happy, and team ahead of schedule.

On the flip side, skipping or underinvesting in quality control in the age of IoT development leads to costly reworks, endless debugging, or worse, a damaged reputation.

Working with WebbyLab means you don’t have to take those risks. We help you build a smarter QC strategy for all components of IoT. A strategy that leads to fewer warranty claims, faster time-to-market, easier scaling, and more confidence at every production stage.