🛠️ In large-scale production, every second counts. An efficient test bench not only validates the product’s functionality but ensures continuous performance, failure reduction, quick diagnosis, and complete traceability. The correct specification is the first step to a reliable, scalable, and integrated system in your process.
A well-specified test bench prevents bottlenecks, reduces rework, and ensures the quality of your product — at high cadence.
🧩 Steps to specify a productive test bench
1. Clearly define the DUT and the test scope
- Which functionalities need to be validated?
- Are there tests that are electrical, mechanical, RF, optical, functional, visual?
- What are the limits of these tests?
- Which interfaces will be tested (Ethernet, USB, UART, I2C, CAN, HDMI, RF, WiFi etc.)?
2. Determine the production volume
- How many DUTs per hour/day?
- This will define whether parallel testing, multiple benches, or rotation with interchangeable jigs will be necessary.
3. Ideal cycle time (Takt Time)
- What is the maximum allowed time per test to maintain the line’s pace?
- Which operations can be parallelized (setup, identification, analysis, recording)?
4. Automation and ergonomics
- Automate repetitive actions (jig closing, code reading, recording, results)
- Apply NR-12 and 5S principles for operator safety and efficiency
5. Complete traceability
- Record of serial number, operator, time, station, results, and measurements
- Integration with database or MES/ERP system
6. Instrumentation and interface
- Select appropriate equipment: power supplies, multimeters, switches, cameras, sensors
- Standardize connections and facilitate maintenance with modular interfaces
📊 How AJOLLY Testing designs benches for high production
AJOLLY Testing combines electronic, mechanical, and software engineering to develop custom test benches with:
- Help to identify requirements and specify techniques and the production process.
- Quick connection jigs with presence detection and monitored life cycles
- Test software (TestStand, LabVIEW, C#, Python, etc.) for automation, parallelism, and debugging
- Integrated instrumentation (PXI, CompactDAQ, GPIB, USB, etc.)
- Dashboards and automatic reports with indicators like FPY, CPK, WIP
- Diagnosis and assisted manual retest mode
- Support for parallel testing and multiple product models
✅ Direct benefits
| Requirement | Industrial benefit |
|---|---|
| Cycle time reduction | Increased throughput without compromising quality |
| Process standardization | Ease of training and reduced variability |
| Integrated diagnosis and rework | Reduction of rejects and increased FPY |
| Digital traceability | Support for audits, quality control, and reliability |
| System integration | Continuous flow with ERP, MES, Power BI and dashboards |
For large-scale production, the test bench cannot be just a step — it needs to be a hub of quality, data, and efficiency.