5 TIpS FoR EnSuRiNg SUpErIoR
PRoDuCtIoN REsUlTs
HOW TO DEPLOY
THE BEST
TEST STATIONS
1.
SOURCING
NOT ALL PARTS ARE
CREATED EQUAL
One of the most important factors for ramping up
high-tech product manufacturing is robust,
automated test stations. If your manufacturing line
breaks down because your stations can’t reliably
test your products, the bottom line will take a hit.
To lower short-term costs, some
test station manufacturers use
substandard parts or inferior
ts!
CoS
processes. Such false economy
typically hits back in the form of
station malfunctions, inconsistent testing, labor
disruptions, RMAs and brand reputation.
AVoId iNfErIoR
PaRts aT AlL
5 Tips for Ensuring Superior Production Results / Averna
VOLUME
The best test stations – like the best products –
are manufactured with superior components
sourced from quality suppliers. And behind any
reputable test-station manufacturing program you
will find a reliable parts sourcing program that
includes:
AND DON’T FORGET
VOLUME
DISCOUNTS.
5 Tips for Ensuring Superior Production Results / Averna
• Supplier, stocking and just-in-time (JIT)
agreements
• Bill of material (BOM) definition
and analysis processes
• Material requirements planning
(MRP) controls
• Alternate supplier and vendor scoring systems
SOURCING: NOT ALL PARTS
ARE CREATED EQUAL
1
2.
PLANNING
MEASURE TWICE,
CUT ONCE
Like the well-known carpenter’s rule, the planning
effort made at the start of the project will be repaid
handsomely once the build-to-print work is underway. So to optimize time, materials and labor,
issues such as these need to be resolved at this
key phase:
• What is the best assembly flow –
1x piece or cell?
• What are the routing and tooling requirements?
• How much floor space and labor will
be needed?
• How much stock will be required and
exactly when?
5 Tips for Ensuring Superior Production Results / Averna
RIgOrOu
PrOcEs
AlL ThE
Simulation is a highly productive planning
approach. By simulating the crucial sourcing and assembly steps, you can ensure
that the most optimal processes are in
place well before the parts arrive or the
labor is scheduled. Typical preparations
at this stage can include:
•
•
•
•
Capacity and MRP material simulations
Kanban and JIT planning
BOM integration
Labor, delivery and inspection scheduling
5 Tips for Ensuring Superior Production Results / Averna
s
SeS MaK
e
nCe!
DiFfErE
SMART PLANNING
ELIMINATES COSTLY
MISTAKES.
PLANNING:
MEASURE TWICE, CUT ONCE
2
3.
ASSEMBLING
ONE STEP AT A TIME
Some OEMs know exactly what they want in a test
station; others rely on test station experts to guide
them with the design, the BOM, sourcing, etc. For
the important assembly phase, the test station
provider should have in place:
mAkE sU
rE eVeR
Y
sTaTiON
iS
iDeNtIcA
L.
• Takt time studies and ramp-up plans
• Visual work instructions and clear
assembly steps
• A multidisciplined team, including software
integrators
• A fully equipped production facility
5 Tips for Ensuring Superior Production Results / Averna
FEEDBACK
A QUALITY
VENDOR KEEPS
YOU IN THE LOOP.
5 Tips for Ensuring Superior Production Results / Averna
Many factors are required to produce high-quality,
high-volume stations. As well as sourcing the best
parts, thorough planning and methodical assembly, a test-station manufacturer should have
state-of-the-art manufacturing processes in place.
Programs like closed-loop feedback and continuous improvement ensure that the vendor is
focussed on maximum efficiency, quality and the
client’s best interests. And the vendor should
also regularly communicate key performance
indicators (KPIs) and action items to its client.
ASSEMBLING:
ONE STEP AT A TIME
3
4.
TESTING
DON’T LEAVE QUALITY
TO CHANCE
It’s one thing to assemble all the components, but if a
part was installed incorrectly or a wiring connection
was missed, there’s a flaw in the system. So you will
need a test program with the following elements to
ensure each test station is capable of thorough,
repeatable testing:
YOuR StAtIoNs,
•
•
•
•
Detailed checklists
Visual and self-inspections
Test results and data analysis
Final quality inspection/sign-off
LiKe yOuR
PrOdUcTs,
NeEd tO Be
FuLlY TeStEd.
5 Tips for Ensuring Superior Production Results / Averna
One key vendor differentiator in test station
replication is test engineering expertise.
All too often, test stations are fabricated by
companies that may have sourcing or assembly skills but do not have any depth in
test engineering.
Consequently, key elements of a quality
station – such as robustness and automation
for reliable and repeatable testing – are simply
beyond their reach. When selecting a
build-to-print supplier, consider the extra
value that test expertise and best practices
can bring to your product quality and
throughput.
5 Tips for Ensuring Superior Production Results / Averna
LOOK FOR DEPTH
IN A VENDOR’S
TEST EXPERTISE.
TESTING: DON’T LEAVE
QUALITY TO CHANCE
4
5.
DEPLOYING
BUILD LOCALLY,
SUPPORT GLOBALLY
It’s obviously not enough to build an impressive fleet
of test stations. They still need to be smoothly moved
and deployed where and when you need them, such
as to a contract manufacturer site in Asia, South
America or Europe.
DOn’T G
aMbLe
WiTh Lo
GiStIcs!
A reputable vendor will need to have
numerous programs and systems in place to
efficiently perform important steps such as
secure crating, local and international shipping,
customs brokerage and site setup.
5 Tips for Ensuring Superior Production Results / Averna
ENSURE
A LONG LIFE
FOR YOUR
STATIONS.
5 Tips for Ensuring Superior Production Results/ Averna
A quality test-station replication service must
also be able to quickly integrate your test stations into a manufacturing facility, conduct site
acceptance tests (SAT) and train local operators
so your production line is up and running as
soon as possible.
And once your new stations are operating, it’s
important to have reliable support services and
programs in place – like spare parts inventory,
and preventive and corrective maintenance – to
ensure your stations are always at maximum
efficiency.
DEPLOYING: BUILD LOCALLY,
SUPPORT GLOBALLY
5
rEaD oUR oThEr eBoOkS
oN tEsT sTaTiON dEsIgN,
tEsT aUtOmAtIoN
WHETHER YOU’RE
A PRODUCT DESIGNER,
ENGINEER OR
TECHNICIAN, LEARN
MORE ABOUT TEST
BEST PRACTICES
FROM OUR EXPERTS _
WHAT WORKS,
WHAT DOESN’T
AND WHAT
THE TRENDS ARE.
AnD MoRe!
eD tHE bRaIN oF
pP
tA
E
w
K,
oO
eB
iS
tH
U
tO bRiNG yO
aTiON dEsIgNeRS.
sT
sT
tE
Y
vV
sA
T
Os
m
R
oNE oF oU
HE RARELY
THIS GUY IS SO DEDICATED TO TEST INNOVATION THAT
AL CHAMBER.
EMERGES FROM OUR LAB AND VACATIONS IN A THERM
A RUMOR IN THE
ALONE. OUR CEO HAS NEVER MET HIM AND HE’S JUST
MANY TECHNICAL
HR DEPARTMENT. STILL, HIS EFFORTS HAVE LED TO
LITTLE FROSTBITE.
AND PRODUCTIVITY BREAKTHROUGHS, IF NOT A
JUsT Don’T TeLl oUr
“TeSt-y” cEO – hE ThInKs
We’Re cRaZy gIvInG AwAy
KnOw-HoW LiKe tHis.
02/2014
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