Electronics testing can be a strategic advantage rather than a compliance hurdle. The challenge lies in designing an approach that aligns business goals with cost efficiency.
Electronic products are complex ecosystems that cannot afford shortcomings. A single weakness can lead to cascading failures, safety hazards, or disappointing user experiences.
Imagine a scenario when a seemingly perfect device with a hidden flaw (e.g., overheating, battery issues, etc.) launches well, but user issues occur within a month. Consequences include recalls and repairs, damaged reputation affecting future sales, and potential lawsuits.
Negligence can be painfully costly in electronics design. Flawlessness is all-important and, roughly speaking, depends on two factors: the experience and expertise of a Design House (R&D) or electronics manufacturing services company (EMS) and thorough testing.
How much testing do I need (and can I have less of it)?
Clients focused on speed to market and cost efficiency may want to rush things forward. They expect that RnD experts know their job and can handle things correctly. That’s usually the case, but the complexity of electronics design and risks involved make testing necessary. However, things can be streamlined by setting the proper foundation.
Electronics design starts with communication. The success of a project relies on design thinking and empathy. Designers need to fully understand a client’s requirements and business goals. They may suggest improvements/simplifications or alternative solutions that meet a client’s needs better. They also have to clarify the potential limitations of the solutions under consideration. Only then can things move forward smoothly , and the actual design work may be as effective as possible.
A critical step in the process is creating the test plan followed by the acceptance criteria which provide the benchmarks confirming the client’s requirements market The test plan, including the mentioned acceptance criteria, act as a bridge between the initial concept and the final product, ensuring common understanding.
Depending on the approach or considered scenarios, a test suite can be based on:
- Quality Testing Plans (QTPs), which outline specific tests, test cases, and methodologies to be used throughout development and production,
- or Design Verification Plans & Reports (DVP&Rs), which focus on verifying whether the design itself is functional in the system.
Testing plans translate the acceptance criteria into actionable steps for the testing and validation team. They are a critical component of the project’s success, as defined by the client and the contractor. Many R&Ds assume that the scope of testing should more or less equal the development time. It’s frequently the case, but the actual ratio depends on several factors, including:
- device complexity: simple devices with well-understood technology might require proportionally less testing time compared to complex, cutting-edge devices with novel features,
- development methodology: testing throughout the development process (agile approach) can reduce the need for dedicated tests at the end,
- regulatory requirements: devices subject to strict regulations will naturally require more comprehensive testing,
- and the client’s risk tolerance.
Ultimately, the scope of testing should rely on a thoughtful evaluation of the project’s requirements (including industry standards and legal requirements) and the client’s priorities.
The goals of testing: a breakdown of test types in electronics design
Approaches to testing vary across companies and projects. Based on our over 20 years of experience and thousands of completed projects, we classify electronic device tests into three groups (which may sometimes overlap):
- functional tests,
- non-standard (abnormal conditions test / failure tests)
- and normative, aka conformity tests.
Let’s give them a closer look.
Functional tests
Functional tests ensure that a device meets its specifications and performs reliably under real-world conditions. They can expose hidden issues in the overall design that might not be apparent through individual component testing. This could be anything from compatibility problems between components to unexpected interactions under specific use cases. Properly performed functional tests allow engineers to identify and fix any potential issues before the product’s debut.
Non-standard tests
Non-standard tests prepare the system for „abnormal” conditions. They address exceptional situations that, nevertheless, can’t be ignored. For example, wireless transmission is interrupted. The signal drops out, and the device loses connectivity. The system should respond appropriately, e.g., by displaying an „out of range” message. Such an issue seems simple to handle, but requires specific test scenarios to ensure comprehensive coverage.
Another critical case is testing for safety under non-standard conditions, such as protection mechanisms in devices powered by hazardous voltages. These safeguards must activate when the product sustains damage, preventing severe consequences like fires or electric shocks. Testing under „abnormal” conditions involves simulating physical damage to ensure these protections work effectively, safeguarding both the system and the user.
For example, many have experienced a blown breaker when a device gets damaged or wet. Non-standard tests are essential to verify that the built-in safety features can handle unexpected events, ultimately ensuring the device’s reliability and user safety.
Normative tests
Last but not least, there are normative tests. They ensure a device complies with regulations and industry standards that guarantee safety, performance, and interoperability for electronic products. Clients often require certification from accredited bodies to ensure the device meets specific standards (such as CE, UL, FCC, VDE, ENEC, etc.). The certification process can be lengthy and costly, affecting the product’s time to market.
Fortunately, preliminary tests conducted in-house can streamline things. With an EMC chamber on-premises, a well-equipped laboratory, a team of experienced engineers, and thousands of hours spent addressing electromagnetic compatibility problems, we can offer clients preliminary testing at reasonable times and costs. This can be part of a broader collaboration or provided as expert consultancy. Ultimately, we can guarantee that the device will pass certification smoothly after our preliminary tests, saving time and resources.
Testing is beneficial, but can it also be cost-efficient?
Thorough testing of electronic devices, even at the mock-up stage, provides invaluable insights into potential problem areas, allowing for early intervention and revealing hidden flaws. Such a proactive approach reduces the risk of certification failures, prevents project delays, and increases speed to market, ultimately benefiting a company’s revenue and reputation.
Investing in thorough testing pays off in the long run but requires initial costs. They can be mitigated in several ways, with some already mentioned above. Overall, increasing cost-efficiency involves:
- transparent communication and setting clear objectives to avoid rework,
- testing earlier to avoid issues later,
- conducting preliminary tests in-house,
- standardization and reuse of testing within a single project (the scope of this approach depends on several factors),
- test automation – a lengthy topic we’ll cover in another article.
In conclusion, effective electronics testing requires balancing risks and benefits while exploring cost-reduction strategies – all with business goals in mind.