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Test Engineer
A test engineer is a professional who determines how to create a process that would best test a particular product in manufacturing and related disciplines, in order to assure that the product meets applicable specifications. Test engineers are also responsible for determining the best way a test can be performed in order to achieve adequate test coverage. Often test engineers also serve as a liaison between manufacturing, design engineering, sales engineering and marketing communities as well. Test engineers can have different expertise, which depends on what test process they are more familiar with (although many test engineers have full familiarity from the PCB level processes like ICT, JTAG, and AXI) to PCBA and system level processes like board functional test (BFT or FT), burn-in test, system level test ( ST). Some of the processes used in manufacturing where a test engineer is needed are: * In-circuit test (ICT) * Stand-alone JTAG test * Automated x-ray inspection ...
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Manufacturing
Manufacturing is the creation or production of goods with the help of equipment, labor, machines, tools, and chemical or biological processing or formulation. It is the essence of secondary sector of the economy. The term may refer to a range of human activity, from handicraft to high-tech, but it is most commonly applied to industrial design, in which raw materials from the primary sector are transformed into finished goods on a large scale. Such goods may be sold to other manufacturers for the production of other more complex products (such as aircraft, household appliances, furniture, sports equipment or automobiles), or distributed via the tertiary industry to end users and consumers (usually through wholesalers, who in turn sell to retailers, who then sell them to individual customers). Manufacturing engineering is the field of engineering that designs and optimizes the manufacturing process, or the steps through which raw materials are transformed int ...
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Center Of Gravity
In physics, the center of mass of a distribution of mass in space (sometimes referred to as the balance point) is the unique point where the weighted relative position of the distributed mass sums to zero. This is the point to which a force may be applied to cause a linear acceleration without an angular acceleration. Calculations in mechanics are often simplified when formulated with respect to the center of mass. It is a hypothetical point where the entire mass of an object may be assumed to be concentrated to visualise its motion. In other words, the center of mass is the particle equivalent of a given object for application of Newton's laws of motion. In the case of a single rigid body, the center of mass is fixed in relation to the body, and if the body has uniform density, it will be located at the centroid. The center of mass may be located outside the physical body, as is sometimes the case for hollow or open-shaped objects, such as a horseshoe. In the case of a d ...
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Final Quality Audit Process
The final quality audit (FQA) process, in the electronic hardware manufacturing world, is the last process flow before shipping a product. This process is established to ensure the unit has gone through and passed all the manufacturing or test process and is in good quality. This process not only includes visual checking of the unit (i.e. labels has been placed properly, no scratches, no dents, all LED/lights are functional) but also checks that the correct firmware and version plus configuration has been loaded properly. It must power up according to specs as well. There are cases where a separate out of the box audit (OBA) process is defined, but most of the time this can be combined as well. OBA is just a visual check making sure that the unit has, again, the correct labels plus all the manuals or other parts that needs to ship with it is also inside the box. Labels from the unit should also match the ones outside the box. Besides checking good quality of the unit, this pro ...
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Vibration
Vibration is a mechanical phenomenon whereby oscillations occur about an equilibrium point. The word comes from Latin ''vibrationem'' ("shaking, brandishing"). The oscillations may be periodic, such as the motion of a pendulum—or random, such as the movement of a tire on a gravel road. Vibration can be desirable: for example, the motion of a tuning fork, the reed in a woodwind instrument or harmonica, a mobile phone, or the cone of a loudspeaker. In many cases, however, vibration is undesirable, wasting energy and creating unwanted sound. For example, the vibrational motions of engines, electric motors, or any mechanical device in operation are typically unwanted. Such vibrations could be caused by imbalances in the rotating parts, uneven friction, or the meshing of gear teeth. Careful designs usually minimize unwanted vibrations. The studies of sound and vibration are closely related. Sound, or pressure waves, are generated by vibrating structures (e.g. vocal cords); t ...
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System Test
System testing is testing conducted on a complete integrated system to evaluate the system's compliance with its specified requirements. System testing takes, as its input, all of the integrated components that have passed integration testing. The purpose of integration testing is to detect any inconsistencies between the units that are integrated together (called ''assemblages''). System testing seeks to detect defects both within the "inter-assemblages" and also within the system as a whole. The actual result is the behavior produced or observed when a component or system is tested. System testing is performed on the entire system in the context of either functional requirement specifications (FRS) or system requirement specification (SRS), or both. System testing tests not only the design, but also the behaviour and even the believed expectations of the customer. It is also intended to test up to and beyond the bounds defined in the software or hardware requirements specific ...
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Regression Test
Regression testing (rarely, ''non-regression testing'') is re-running functional and non-functional tests to ensure that previously developed and tested software still performs as expected after a change. If not, that would be called a '' regression''. Changes that may require regression testing include bug fixes, software enhancements, configuration changes, and even substitution of electronic components. As regression test suites tend to grow with each found defect, test automation is frequently involved. Sometimes a change impact analysis is performed to determine an appropriate subset of tests (''non-regression analysis''). Background As software is updated or changed, or reused on a modified target, emergence of new faults and/or re-emergence of old faults is quite common. Sometimes re-emergence occurs because a fix gets lost through poor revision control practices (or simple human error in revision control). Often, a fix for a problem will be "fragile" in that it ...
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Ongoing Reliability Test
The ongoing reliability test (ORT) is a hardware test process usually used in manufacturing to ensure that quality of the products is still of the same specifications as the day it first went to production or general availability. The products currently in the manufacturing line are randomly picked every day with a predefined percentage or numbers and then put in a control drop tower or an environmental chamber. Control drop simulates physical interactions on the product, while environmental chamber simulates the stress profile of thermal cycling, elevated temperature, or combined environmental stresses to induce fatigue damage. The profile should stimulate the precipitation of latent defects that may be introduced from the manufacturing process but not remove significant life from the product or introduce flaws to risk failure during its intended mission. highly accelerated stress test The highly accelerated stress test (HAST) method was first proposed by Jeffrey E. Gunn, Su ...
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Insulation Test
A dielectric withstand test (or pressure test, high potential or hipot test) is an electrical test performed on a component or product to determine the effectiveness of its insulation. The test may be between mutually insulated sections of a part or energized parts and electrical ground. The test is a means to qualify a device's ability to operate safely during rated electrical conditions. If the current through a device under test is less than a specified limit at the required test potential and time duration, the device meets the dielectric withstand requirement. A dielectric withstand test may be done as a factory test on new equipment, or may be done on apparatus already in service as a routine maintenance test.Paul Gill (2009), ''Electrical Power Equipment Maintenance and Testing'', Second Edition, CRC Press, 1574446568, page 459 Voltage withstand testing is done with a high voltage source and voltage and current meters. A single instrument called a "pressure test set" or "h ...
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Highly Accelerated Stress Screening
A highly accelerated life test (HALT) is a stress testing methodology for enhancing product reliability in which prototypes are stressed to a much higher degree than expected from actual use in order to identify weaknesses in the design or manufacture of the product. Manufacturing and research and development organizations in the electronics, computer, medical, and military industries use HALT to improve product reliability. HALT can be effectively used multiple times over a product's life time. During product development, it can find design weakness earlier in the product lifecycle when changes are much less costly to make. By finding weaknesses and making changes early, HALT can lower product development costs and compress time to market. When HALT is used at the time a product is being introduced into the market, it can expose problems caused by new manufacturing processes. When used after a product has been introduced into the market, HALT can be used to audit product reliab ...
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Highly Accelerated Life Test
A highly accelerated life test (HALT) is a stress testing methodology for enhancing product reliability in which prototypes are stressed to a much higher degree than expected from actual use in order to identify weaknesses in the design or manufacture of the product. Manufacturing and research and development organizations in the electronics, computer, medical, and military industries use HALT to improve product reliability. HALT can be effectively used multiple times over a product's life time. During product development, it can find design weakness earlier in the product lifecycle when changes are much less costly to make. By finding weaknesses and making changes early, HALT can lower product development costs and compress time to market. When HALT is used at the time a product is being introduced into the market, it can expose problems caused by new manufacturing processes. When used after a product has been introduced into the market, HALT can be used to audit product relia ...
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Environmental Stress Screening
Environmental stress screening (ESS) refers to the process of exposing a newly manufactured or repaired product or component (typically electronic) to stresses such as thermal cycling and vibration in order to force latent defects to manifest themselves by permanent or catastrophic failure during the screening process. The surviving population, upon completion of screening, can be assumed to have a higher reliability than a similar unscreened population. Overview Developed to help electronics manufacturers detect product defects and production flaws, ESS is widely used in military and aerospace applications, less so for commercial products. The tests need not be elaborate, for example, switching an electronic or electrical system on and off a few times may be enough to catch some simple defects that would otherwise be encountered by the end user very soon after the product was first used. Tests typically include the following: * Temperature variations * Vibration tests * Pressure ...
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Burn-in
Burn-in is the process by which components of a system are exercised before being placed in service (and often, before the system being completely assembled from those components). This testing process will force certain failures to occur under supervised conditions so an understanding of load capacity of the product can be established. The intention is to detect those particular components that would fail as a result of the initial, high-failure rate portion of the bathtub curve of component reliability. If the burn-in period is made sufficiently long (and, perhaps, artificially stressful), the system can then be trusted to be mostly free of further early failures once the burn-in process is complete. Theoretically, any weak components would fail during the "Burn In" time allowing those parts to be replaced. Replacing the weak components would prevent premature failure, infant mortality failure, or other latent defects. When the equivalent lifetime of the stress is extended ...
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