Auto Parts Maker Witnessed a 6x Boost in Test Throughput

Introduction

The vast majority of printed circuit board assemblies are getting smaller due to the ongoing efforts of semiconductor manufacturers to pack more functionality into ever-smaller packages. It is becoming more common to produce high-volume electronic modules with 10 or 20 identical boards on a single panel. The typical testing process, however, is incapable of keeping up with the significant efficiency and throughput gains driven by panel density on SMT lines.

There is now a new technology on the horizon that can simultaneously perform electrical functional tests of all the boards in the panel. This new technology makes it possible for these tests to take place in parallel, increasing test throughput significantly.

In this case study, we will demonstrate how we helped one of the world's leading auto parts manufacturers transform their existing test solutions to the challenges posed by highly panelized boards used in the automotive electronics industry.

The Challenge: Improving and Expanding Manufacturing Test Process for Highly Panelized PCBAs

Prior to switching over to the Keysight i7090 massively parallel board test system, the customer performed the same testing function of their high-runner, low complexity boards with an in-line MDA (Manufacturing defect analyzer) system and an external ISP (In-System Programming) that contains two programming tools. As shown in Table 2 below, it is evident that these methods were inefficient and unable to keep up with the throughput capacity due to the long test time. The mismatch in throughput capacity compels the customer to find new ways to improve, accelerate, and expand their electronic PCBA manufacturing test process.

The Solution: Keysight i7090 Massively Parallel Board Test System

Motivated by the need to meet the test capacity, the customer has reached out to our local team because we have one of the most comprehensive ICT and boundary-scan test solutions in the industry. Following several discussions and considerations, they have identified the Keysight i7090 as the solution that would best meet their needs.

The core configuration of the i7090 is variable and not confined to a fixed number of rows, which reduces overall computing costs. Because of the i7090's flexibility and scalability, the customer could configure the system to meet their high-runner and low-complexity board test requirements by configuring it with 6 cores, 12 analog cards, and 2 carrier cards (with 3 units of SMH Flash Runners). With a 6-core i7090 tester, the customer can now perform the test for 6 boards concurrently rather than queuing for the test, which will significantly increase board test speed.

The Result: Smaller Footprint and a 5x Improvement in Test Throughput

Smaller footprint

By adopting the i7090, the customer has consolidated the MDA system and an ISP tester into a single test system, resulting in a more streamlined test process. Additionally, the smaller footprint of i7090 has also allowed the customer to make the most of the manufacturing shop floor.

One fixture, application, and a test program for all

With the Analog In-circuit test and ISP integrated into the i7090, the operators only have to familiarize themselves with a single user interface and maintain a single test program. Furthermore, only one test fixture application is needed with ISP integrated, thus reducing the storage space and maintenance cost for two different test strategies. 

Faster test time and higher test throughput

The magnitude of the increase in test throughput was deemed the most valuable outcome. The results of the tests presented in Table 3 show a significant reduction in total test duration, which is approximately 6 times better than the previous test systems. As a result, the customer has added a new project to the test line (Board 3) and has even surpassed their expectations.