Assembly
centric assembly standard are easily
identified by their use of one or another
generic off the shelf software packages.
This probably reflects the fact that the
lion’s share of assemblies has been
configured by machine builders who
have little training or inclination to
master software engineering.
In truth, test centric assemblies
require expertise in both mechanical
engineering and software engineering.
In most cases custom software for
test intensive assemblies is actually less
expensive than a generic off the shelf
Issue III 2009
application because it is designed to
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meet real business needs and does not
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encumber users with the costs for
program features and functionality that
is not actually required. Moreover, many
general applications are not especially
easy to use, or do not reflect the real
data handling requirements of the
application. Custom software for test intensive assembly can helps cut costs for
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Most test applications require manufacturers at any level of expertise
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software that works in real time, for
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example, which is usually not the case
with off the shelf packages. It is plant wide networks for analysis. explains why the most savvy machine
35
important to have the means to view Internet based remote diagnostics are builders around the world are now
real time traces of test instrumentation another feature of the best in class test incorporating applications engineers
transducers’ performance, as opposed centric assemblies. with a sole focus on testing into their
to simple test cycle times. Custom software development for project development teams.
Slower and less detailed test centric solutions starts with The improvements to be expected
applications do not process data quickly identifying business goals as to how the from a test centric assembly approach
enough to provide for meaningful test data and information garnered during are not trivial. Leak test and functional
control and/or test method calibrations. testing will be used not just in initial test cycle times can be decreased 25% -
If the required data analysis is more production but also during the entire 70% in the best in class examples, and
complicated than generating a simple lifecycle of the product being produced yields increased proportionally. There
line graph, the off the shelf software in the assembly and test operation. are numerous cost savings from
packages that are commonly used This is of growing importance to implementing a test centric assembly
similarly fall short. the many industries that now want approach.
The best in class custom software processes to attach data to products First, is the greater return from
for test centric assemblies will also from cradle to grave to assist with higher yields in test centric assemblies
automatically calculate R&R recalls or reducing time to market in by using better fixture designs and
percentages based on the number of new product development cycles. customized test instruments and related
trials performed. software and high throughput chasses
How networks are built is also Multiple cost savings designed for test intensive operations.
important in fully integrating testing A tell tale sign of a less than optimal Second, in process testing cuts the
into assembly operations. When there assembly and test operation is one added costs for finishing products that
are steep requirements for testing, where the machine builder defines will ultimately be deemed defective.
there is inherently a lot of data that testing gauge R&R in terms of those Third, defective parts are not
typically has to be processed and also proffered by the manufacturers of the misclassified as “good” parts and
sent to a plant wide network. test instruments. returns are minimized.
BUS compatibilities need to be Gauge R&R of the entirely Last, but not least, time to market
considered. State of the art test centric assembly and test solution is what for new product development can be
assemblies have Ethernet capabilities counts, and this is what must be decreased by as much as 10% by
that allow the huge datasets from guaranteed to users of the test centric mining extensive test data from
intensive testing to be distributed to assembly and test solution. This assembly and test operations.
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