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TEST SYSTEMS AND JIGS
Delivering your production test systems and jigs, seamlessly out of your development project
Production test systems and jigs are often left to the last moment and sometimes even unbudgeted. Yet the cost of testing can exceed unit manufacturing costs and of course, the earlier you detect faults the easier it is to correct. At Genesys, development of test systems and jigs are a standard part of product development projects.
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What we do: We systematically deliver all the elements (see below) needed to test your product as it comes of the manufacturing line, to ensure the end user gets the product you promised with no flaws.
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We do it properly: We develop test jigs and associated systems like a well-managed project in its own right, with requirements definition, and verification/validation of all software and hardware, to ensure the quality of your testing process.
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We make it easy: We take away all the headaches by dealing with test jig manufacturers on your behalf and ensure your product is working properly before shipping, allowing you to focus on your customers and other business processes that are more core to what you do.
Design for Testability
Many people treat testing as an after-thought in the PCBA design process but it is often the biggest bottleneck and one of the costliest parts of the production process. It pays to address testability early in the design process. Design for testability is part of our broader Design for Manufacturing approach, outlined further on our Manufacturing Logistics page. Key factors we consider are:
Layout design: We ensure that PCBA designs are optimised for testing including consideration of test probe points to facilitate adequate testing and integration with any bed-of-nails test jigs.
Self-testing: As much as possible we incorporate self-testing into the device's firmware to minimise the testing that needs to be done during production.
Panelisation: Where testing times are long, we aim to test multiple PCBAs in parallel on a single panel.
Manufacturer liaison: We work with the manufacturer to provide early visibility of what tests will be required, the set up of the test systems and data recording requirements, so that your initial production cost quotes are as accurate as possible.
Test requirements
Like any properly managed project, cost-effective testing systems and jig development starts with defining the requirements. Key considerations include:
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Testing approach: We firstly determine what kind of test system you require, which will depend on the volume of your production and vary greatly from proof of concepts through medium volume pilot runs to mass production. The aim is to minimise testing time in a way that is cost-effective.
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Test system requirements: The next step is to define production programming & test requirements for the PCBA(s) and the final assembled unit.
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Test fixture specification: Where a specific test fixture is required, such as a bed-of-nails test jig, we specify the requirements for these also.
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Test fault coverage analysis: We formally identify what tests are required based on the product requirements and risk analysis (if applicable) and assess the effectiveness and adequacy of the testing process.
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Testing procedures: The test system will include detailed processes and procedures that must be followed exactly to ensure the devices are correctly tested and the right records produced and stored. These procedures are developed in the context of the broader test requirements.
Production Test Jig
(PTJ) development
Efficient test systems and jigs can deliver as many savings as optimised designs. Also, its important that you own the IP of the PTJ so you can transfer manufacturers if needed. The following service are all aimed at minimising the unit testing cost.
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Test fixture requirements: Text fixtures are projects in their own right, with development of requirements, development and verification.
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PCBA development: Where a text fixture requires its own PCBA to execute the test programs, this is developed, again with requirements and verification. A custom PCBA is recommended to avoid a wiring "rat's nest" and facilitate easy PCB assembly where multiple PTJ units are required.
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Nailbed development: Where a Bed of Nails is required as part of the PTG, we specify the nailbed and liaise with a specialist manufacturer to have this produced.
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Jig calibration and maintenance: We define calibration procedures, manage the measuring equipment and the ongoing maintenance tasks to ensure the test system continue to operate as required. See our Production Management page for more information.
Test software
While a wide range of electrical verification type tests are carried out only once during the design phase, some tests must be undertaken on every single unit manufactured. Some test software will be embedded in the Device Under Test (DUT) and some will be on a connected PC. Key aspects to consider include:
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MCU programming: Ensuring the right software image is loaded on the device.
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Functional verification: Ensuring all the circuit modules are working correctly.
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Calibration: Many devices require aspects of the device to be calibrated. For example, if the device's operation depends on its orientation.
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Power supply: Most modules are depended on correct operation of the power supply interface, conversion and monitoring, so this is a common test.
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Records storage: Production test records are generated automatically and stored on the PC as well as the device's EEPROM where appropriate.
Assembly, verification & validation
Making sure the Production Test Jig (PTJ) is working correctly is critical to reliability. Following are the key services we offer:
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Assembly and instructions: Genesys will normally assemble, integrate and test the PTJ and where we don't detailed instructions are provided.
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Verification and commissioning: We will test the assembled PTJ to ensure it is operating correctly according to the design inputs and formally commission it on-site.
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Training: We will train production personnel in the use of the test system.
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Validation: Finally, we will validate that the testing system is working as intended by conducting on-site audits of the production facility.
Compliance and traceability
For medical devices and other devices subject to regulatory oversight, a range of documentation is required to prove the test systems are effective in producing a product that is safe to use. This documentation will form part of the official Device Manufacturer's quality management system. Key features of our service that supports the regulatory compliance process include:
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Planning and procedures: Genesys will produce all the required plans under the necessary document controls, including verification plans, test protocols and more.
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Traceability: We provide verification and validation logs to prove that the test system meet all of the requirements and complies with the plans.
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Supplier audits: We can conduct audits of the electronics manufacturer used to manufacture and test the PCBAs (see our Production Management services) including monitoring of PTJ calibration and maintenance.