tools and controls used to provide quality manufacturing test

EBTW 2005, Tallinn, Estonia

EBTW05

Tools and controls used to provide quality Manufacturing Test Management within EMS (Electronic Manufacturing Service) providers.


EBTW05 AgendaIntroduction to Manufacturing Test

Challenges with introduction and control of a test processGeographical locationGrowing Product complexityProduct tracking and control

What the solution isTest AutomationRemote AccessIntegrated Forced route system

Summary

Q & A


EBTW05 Introduction to Manufacturing Test

Many OEM (Original Equipment Manufacturers) are outsourcing product manufacturing to EMS providers

This presentation is based on a solution where the OEM providestest equipment and test solutions to the EMS

Example of a Manufacturing Test Process

FunctionalTest

Packaging ShippingSoftwareDownload

SystemTest

Computer Computer

SD

Smart-UPS

6 2 0

www.apcc.com

TestEquipment

SD

D E F I NI T Y 0 3 4

TestEquipment

SD

HEWLETTPACKARD

TestEquipm

ent

Computer

Final QualityAssurance Test

Computer


EBTW05

We are here (OEM)

Challenges with introduction and control of a test process (1)

Geographical Location

LanguageE.g. Chinese, French, Malaysian.

Time Zones+1hr --> - 8Hrs

Culture

High staff turnoverAsia region

EMS

EMS

EMSOEM

Laptop

Manufacturing

Manufacturing

Manufacturing


EBTW05

Growing product complexity

New products and technologyContinuous product introductionLimited knowledge of product testing with EMS

Product includes high mix low volumeIncrease in Test SetupsIncrease risk to product quality

Example of Main Unit (26 types)

Example of Option Card (9 types)

Challenges with introduction and control of a test process (2)


EBTW05Challenges with introduction and control

of a test process (3)

Product tracking and controlDefinition

Monitor product through the test processEnsures the product is tested in the correct sequenceEnables manipulation of test data to monitor yields etc.

Possible problems with depending on EMS in-house tracking systemEMS has no systemCan cause delays to integrate with OEM Test softwareNeed to change OEM Test SoftwareNot including all requirements needed by the OEM


EBTW05

Test AutomationGeneric Operator front-endResult data generation and collectionDiagnostic automation

Integrated Forced Route SystemServer provided on siteEach Test Step only executes if the previous step is passOnly generates a box label when all steps passEasy manipulation of the test data

Remote AccessSecureCost effectiveProvides workable speed

Solutions Provided


EBTW05 Test Automation (1)Generic Operator Front-end (on all test stages)

Product Software

Measurements

Run Test

Example of Operator Frontend (created with HP-Vee Software)


EBTW05 Test Automation (2)

Result Data Generation and Collection

InternetExplorer

ApacheServer

PHP3

Test Results:Serial No.: ????

TEST STAGE 1 TEST STAGE 2 Test ServerBOX LABEL PRINT

HP-VEEGUI

ODBCDrivers

HP-VEEGUI

CODESOFT

ODBCDrivers

WEB Access

InternetExplorer

SQLDatabase

InternetDDEDrives

Labview

ODBCDrivers

EMS Site OEM Site


EBTW05 Result examples (1)Flat Text File

Original solution for result dataUseful option if EMS want to use in-house tracking

Print time: Tue 29/Jan/2002 18:30:45MainUnitSN: 02R201070679, MainUnitMAC: 00601D339E3A, OptionCardSN: , OptionCardMAC: Test Station: FUT5Test Software: 2.00.01Test started at: Tue 29/Jan/2002 18:08:15==============================_ Phase / Step, Result, HighLimit, LowLimit, Description.- Phase 000 {"Step010", "02R201070679", "Invalid", "nnccnnnnnnnn", "Verify Main Unit SN label entry"}- Phase 000 {"Step020", "00601D339E3A", "Invalid", "00601Dcccccc", "Verify Main Unit MAC label entry"}- Phase 010 {"Step020", 0.287853, 0.4, 0.2, "Check initial current drain PS1+PS2"}- Phase 010 {"Step030", 48.0061, 48.96, 47.04, "Check input voltage PS1"}- Phase 010 {"Step032", 48.0148, 48.96, 47.04, "Check input voltage PS2"}- Phase 010 {"Step040", 1, 1, 1, "Verify HITE is up"}- Phase 010 {"Step050", "Master Board: X2L42-DI", "FAIL", "X2L42-DI", "Verify HITE started AM1X2L42-DI"}- Phase 010 {"Step080", 0, 0, 0, "Verify I2C connection to P7 Pins 13,14 and LP1.1 POTs"}- Phase 010 {"Step090", 0, 0, 0, "Verify I2C connection to P7 Pins 13,14 and LP2.1 POTs"}- Phase 020 {"Step010", 0, 0, 0, "HITE 12,2 display main unit inventory"}- Phase 020 {"Step010", 1, 1, 1, "HITE 18,4 Verify no option card installed"}- Phase 030 {"Step010", 0, 0, 0, "HITE 2,1 Datapath"}

Partial Example of a result file


EBTW05 Result examples (2)SQL Database

Easy access of data using Internet Explorer™Monitor fail yields

Compare testersProduct

Partial Functional results for unit 02R209094020


EBTW05 Diagnostic Automation

Tester DiagnosticsDecreased tester downtimeAbility for OEM to debug remotelyCan provide preventive maintenance

Product DiagnosticIncrease efficiency of product debugIncrease technician's knowledge of test setup

Example of a Functional Test Stage

Example of a Product Diagnositic Front-end


EBTW05 Integrated Forced Route System

Key FeaturesIntegrated into the Test Software at each test stage.

Each test stage insures a pass result on previous step before proceeding.

Pre-defined route for each UUT

Automatic box label & Conformance report printout

TestStage 1

TestStage 2

ResultData

Pass /Fail

Pass / Fail

SQLDatabase

ResultData

Debug Rework

Debug Rework

Packout

YES

NO

YES

NO

Box LabelGeneration

Pass / Fail

YES

DebugNO

ResultData

Example of a Test Route for aparticular Card


EBTW05 Current Remote Access optionsISP Access (Internet Service Provider)

China Telecom ADSL (Broadband) LinkConnection is always onOEM Corporate FirewallSSH server/client for secure InternetCost effective

ISDN Dial-upFast dedicated line

SecureCould be expensive

(CM to Control connection)

OEMTest Server

RS CS TR RD TD CDTALK / DATA

TALKISDN

Modem

Internet

OEM TestNetwork Firewall

EMS connectedvia ISDN

TelephoneNetwork

OEM to EMS Network connections

OEM Test ServerNT4, Cygwin& SSH Server

OEM TestNetwork

OEM TestNetwork

OEMSSH Client

OEM CorporateFirewall

OEMTest Server

OEMTest Engineer PC

EMS connectedvia Internet

RS CS TR RD TD CDTALK / DATA

TALK

ISDNModem


EBTW05 SummaryThe proven tools and controls used to provide quality Manufacturing Test Management within EMS locations are:

Test Automation High quality test coverage Easy operation of test stepsResult data for all product tested

Integrated Forced Route SystemAlways available from start with new EMSEnsures full test coverageDatabase provides easy manipulation of results

Remote AccessReal time remote debug Reduced machine downtimeSupports multiple siteCentral data consolidation


EBTW05 Q & A

Questions and Answers….


EBTW05 Backup slides

BACK-UP SLIDES

tools and controls used to provide quality manufacturing test

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