Production Management and Quality Testing System Manages Distributed Manufacturing of Telecommunication Boards

Author(s):
Shahzad Sarwar - Averna Technologies
Daniel Cox - Averna Technologies, Inc.

Industry:
Telecommunications

Products:
LabVIEW, NI TestStand

The Challenge:
Implementing anautomated and distributed production controland quality testing system to manage a range of new products assembled and tested at different contract manufacturer sites.

The Solution:
Integrating Averna’s Proligent, a production management and testing system, National Instruments TestStand and LabVIEW, and written test cases with an MS-SQL database to achieve a cost-effective and timely implementation of a highly reliable and functional production and quality testing system.

System Requirements
Our customer’s new product line was targeted to produce large numbers of networking hardware boards that require a flexible, reliable, and traceable quality testing setup. The customer needed to centrally manage the product flow, test criteria and results, version and revision specific test procedures, and several other operational details all for a set of distributed product lines located at different and remote contract manufacturer sites. Our customer also needed to maintain all test specifications, procedure sequences, and results in a traceable fashion, and they needed different levels of access to interact with managerial, engineering, or operational parts of the production and testing system. An open architecture and flexible test code development environment successfully integrated an extensive range of hardware including power supplies, oscilloscopes, signal generators, optical switches, flash programmers, and a close interface to work with self-testing features of the products using RS-232, GPIB, and JTAG protocols.

System Design
Proligent provides a close parallelism between real-life production and quality testing steps with extensive features for production management and testing so the user can create new products, define production process, and specify process operations. These engineering tools have extensive editing capabilities to ease both product and process management activities. These features became useful in defining and managing the product flow details.

For quality testing, some of the process operations are associated with test case modules. These modules carry out the actual interface with hardware and execute test logic. Proligent provides a general framework for test case development and combines these in test sequences the customer can use with TestStand test executive. The sequence definition module allows a one-window access to existing repository of test sequences, version management, test station assignment, and test sequence deployment combined with general sequence editing features. The availability of instrument drivers, ease of integration of native code modules, along with support for serial, GPIB, and Ethernet communication made it a natural choice to write the test case modules in LabVIEW.

Proligent also manages the production logistics including inventory, allocation, and calibration records of test instruments. Combined with its instrument command definition module, it provides an abstraction layer between the test cases and instruments that deliver interchangeability without modifying the testing code. The Proligent execution module performs the shop floor operations needed for the overall system. Running in conjunction with TestStand, it updates test software and testing criteria in real-time, provides an operator interface with test progress-monitoring, aids in unit failure and repair reporting, and keeps track of test history of units under test.

Proligent and database tables exchange all process description and test performance data through SQL. Product classification, test sequences, test case modules, along with their version and revision history, are maintained in a database providing complete traceability of production and testing evolution. Testing results with station-related details and execution times are all recorded in appropriate database tables and available for future use.

The customer maintains a local database at each remote test station that is updated in real time during execution, and the testing data is periodically replicated to a central database. Each time, before executing a new test case, the execution module synchronizes the local software version and test criteria with the central database. With the exception of the central database, all database instances are implemented using MSDE, and require no additional licensing costs. Distributed databases also permit an operational reliability that can tolerate temporary network failures.

Proligent’s data viewer module offers access to test data and enables the user to extract testing yield and trending information. Report generation capabilities of LabVIEW and Crystal Report are exhaustively used to generate production and test summaries users can view through Internet browsers with Active Server Pages. Complete test outcomes for each unit are available through data viewer, and summary reports are provided while grouping the data in categories defined per test station, process, or instrument. Statistical process control is possible with full access to testing data that can be elaborated to reveal sensitive parameters for an efficient production and quality testing.

Conclusion
We created a complete production and quality testing system with an efficient and cost-effective implementation that matched the needs of a distributed and enterprise-wide integrated system with multilevel access to production and testing tools. A collaborative integration of LabVIEW, TestStand, SQL server, Crystal Report, and ASP technologies combined with hardware drivers and embedded programming tools created a functional and reliable setup that expedites and facilitates production and testing operations while saving both time and money spent on these operations.

For more information, contact:

Averna Technologies

700 Wellington, Suite 1400

Montreal, OC H3C IT4, Canada

Tel: (514) 842-7577

Fax: (514) 842-7573

E-mail: contact@averna.com

Author Information:
For more information on this Case Study, contact:
Daniel Cox
Averna Technologies, Inc.
87 Prince - Suite #140
Montreal H33 2M7
Canada
Tel: (514) 842-7577
Fax: (514) 842-7573
info@averna.com

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