Test Dispatch - Oct 2025 Newsletter
Testdispatch-Newsletter-B-Makkal
Test Engineering: Fact or Myth?
Think you know the myths from the realities of test automation? See if you can tell which of these statements are true.
1. Fact or Fiction: Automated test systems are always faster than manual testing.
Answer : Fiction
Explanation : Automation is often faster, but not always. For low-volume production or very simple, short tests, the time and cost spent developing the automation software and hardware can be greater than simply testing manually. Automated systems generally only pay off when volume is high or the test requires high precision/repeatability that humans cannot achieve.
2. Fact or Fiction: Automation reduces the variability in measurement results compared to manual testing..
Answer : Fact
Explanation : Automated systems eliminate human factors like inconsistent probe placement, delayed button presses, and reading instruments at slightly different times. This drastically increases repeatability and reduces the standard deviation of measurements.
3. Fact or Fiction: You can use a Design Validation test setup directly on the manufacturing line.
Answer : Fiction
Explanation : Design Validation (DV) setups are built for engineering flexibility, deep data logging, and uncovering all potential failure modes. Manufacturing End-of-Line (EOL) testers must be optimized for speed, simplicity, robustness, and low cost. The DV setup is almost always too slow, complex, and delicate for a high-throughput factory.
The Value of Data Traceability
In modern manufacturing, collecting a pass/fail result from a test is no longer enough. The real value is in capturing and logging every measurement from every test point. This data, when integrated with a Manufacturing Execution System (MES), provides full traceability.
It allows engineers to perform root cause analysis, track trends, and identify potential issues before they cause widespread defects. This data-driven approach is key to achieving continuous quality improvement.
A Test Solution for a Wireless Smoke Alarm
We recently had the opportunity to develop a custom End-of-Line tester for a new wireless smoke alarm. The challenge wasn't just to verify the basic functionality but to ensure the device's complex wireless signals were accurate and reliable. Read the full story: Precision Wireless Testing for Smoke Alarms with LabVIEW
By using a custom, RF-shielded enclosure and a Bed-of-Nails fixture, we created a repeatable test environment that allowed us to perform precise RF measurements and validate the device's core communication features. This project showcases how a tailored hardware and software solution can solve even the most challenging product validation tasks.