Major Product Vendor with Onshore and Offshore Manufacturing Strategy
Design and develop portable, stand-alone automated test stations to functionally test PWB (Printed Wiring Board) assemblies, supporting the client’s transition from onshore to offshore contract manufacturers.
The client’s manufacturing strategy required an agile testing solution that could support their onshore production while seamlessly transitioning to offshore manufacturing facilities. Key requirements included:
Portable and stand-alone test fixtures.
Compatibility with existing PWB assembly test points.
Automated and user-friendly testing with clear pass/fail reporting.
With tight timelines and a need for precision, the client turned to Impact ES–Rhode Island for a solution that would ensure consistent quality across manufacturing sites.
Impact ES–Rhode Island developed a series of portable, stand-alone test fixtures leveraging advanced engineering and software integration.
Partnered with a vendor specializing in bed-of-nail mechanical fixtures to create custom test fixtures.
Defined bed-of-nail contact points using the UUT (Unit Under Test) PWB assemblies’ existing test points and wiring based on a detailed test plan.
Combined off-the-shelf components, including digital/analog test electronics, JTAG programmers, and power supplies, with custom-designed electronics to meet testing requirements.
Designed a robust internal hardware system for accurate and repeatable testing.
Utilized National Instruments LabVIEW Stand to develop an intuitive and automated testing sequence, complete with control and reporting functionalities.
Created missing lower-level drivers to ensure seamless communication with the hardware components.
Delivered a user-friendly graphical interface for operators, including automatic pass/fail reporting and report generation.
Impact ES–Rhode Island’s solution provided the client with a highly effective, portable, and automated testing system. Key results included:
Enhanced Productivity: Reduced testing time and streamlined workflows with
automated sequences.
Scalable Design: Fixtures easily transitioned between onshore and offshore manufacturing facilities.
Comprehensive Reporting: Clear and automated pass/fail results with detailed reporting for quality assurance.
User-Friendly Operation: Simplified graphical interface enabled operators to quickly learn and execute the tests.
Impact ES–Rhode Island’s expertise in mechanical, electrical, and software integration enabled the creation of a reliable and flexible test solution.
The combination of National Instruments Test Stand and custom driver development ensured a seamless and user-friendly testing experience.
The portable design and robust documentation supported the client’s manufacturing strategy, ensuring consistent quality across locations.
This project showcases Impact ES–Rhode Island’s ability to deliver tailored, high-performance test solutions for complex manufacturing challenges.
