Solution Offering
Production Tester
Production testers verify that every manufactured unit meets its specification before it leaves the line. Sasken designs and builds the test electronics, fixtures, automation software, and measurement integration required, for PCB-level and fully assembled products.
Overview
Why choose Sasken for production test solutions?
Sasken delivers end-to-end production test solutions covering test concepting, system architecture, design, deployment, maintenance, and future upgrades. Our teams combine electronics, mechanics, software, and measurement expertise to build board-level testers, calibration systems, and end-of-line testers.
With over 30 years of experience in product development, production support, and test automation, we develop testers that verify product performance and generate the production data needed for traceability and continuous quality improvement.
Key benefits include:
- Test systems designed by engineers who also develop products
- Electronics, mechanics, software, and measurement expertise under one roof
- Access to Sasken laboratories and measurement environments
- Support from test concept through deployment, maintenance, and upgrades
Core Expertise
Core expertise
We develop testers for the point in your process where a quality gate is needed, from bare board to finished product. Each tester is specified around the product’s real failure modes and the throughput the line has to reach.
Core competencies include:
- Board-level and in-circuit functional testers
- End-of-line testers for assembled products
- Calibration and alignment systems, including RF and audio
- Test fixtures, jigs, adapters, and control electronics
- Mechanical test automation — measuring mechanical behaviour, and operating the product while it is measured
Our experience includes communication devices, satellite terminals, smart metering products, industrial automation systems, audio products, automotive platforms, and safety-critical equipment.
Optimization
Performance and optimization
Effective testing starts during product development. Test access, measurement points, and diagnostic coverage are inexpensive to add while the schematic is still open, and expensive to retrofit once a design is released.
We work closely with our electronics, PCB layout, RF, antenna, software, and mechanics teams so that testability is addressed early, giving reliable fault detection and faster troubleshooting throughout the product lifecycle.
How we create value:
- Design-for-testability support and test point definition
- Test coverage defined against real product failure modes
- Test time reduced through sequencing and parallel measurement
- Root cause analysis and fault diagnostics
Before handover we verify repeatability on the delivered station with repeated runs on reference units, and correlate results between testers when several are delivered, so measurements stay comparable across shifts and sites.
Deep Dive
Advanced capabilities
Sasken specializes in demanding tester projects: RF and wireless measurement, acoustic testing, mechanical and electromechanical test automation, multi-DUT fixtures, and integration into existing production lines. Solutions range from standalone test stations to fully integrated production systems.
Specialized expertise includes:
- Automated board-level and end-of-line test systems
- RF and wireless product testing
- Audio and acoustic production testing
- Mechanical property testing, and mechanics that operate the product under test
- Production databases, traceability, and reporting integration
Where a product has to be operated to be tested, the actuation and the measurement run from the same sequence — which is the practical reason our electronics, mechanics and software engineers sit in one project rather than three. A complete delivery can include test electronics, fixtures and mechanics, control software, measurement equipment integration, manufacturing documentation, commissioning, operator training, and maintenance support. We also modernize testers already in production, replacing obsolete instruments or control PCs and porting existing test sequences to extend a proven station’s life.
Tools & Tech
Tools and methodologies
Sasken builds on established test automation platforms and standard measurement instruments rather than proprietary frameworks, so delivered systems can be maintained and extended by your own teams.
Tools and facilities include:
- Test automation in NI LabVIEW, TestStand, Python, C, and C#
- Oscilloscopes, DMMs, RF instruments, power supplies, and custom measurement electronics
- Instrument and device interfaces including SCPI/VISA, GPIB, USB, LAN, CAN, SPI/I²C and JTAG
- Custom fixtures, adapters, and control electronics for multi-DUT and in-line use
- Production result databases, unit-level traceability, and automated result analysis
Close collaboration between our design, test, and manufacturing teams keeps deployment efficient and allows testers to evolve with the product.
AI in Production Test
AI where it belongs in a tester — and nowhere else
A production tester is the wrong place for a system that guesses. So the measurement and the verdict stay in deterministic code, and AI works on everything around them — the data the tester produces, the code needed to produce it, and the questions nobody has time to ask of a database with millions of rows.
The verdict stays in code
- Pass and fail are computed by the test sequence, never by a model
- The AI layer reads the result database — it has no route to an instrument
- Every statement cites the measurements behind it
- A person approves anything that becomes a record
A production log is conformance evidence. A model that could change a verdict would destroy the audit trail.
Result analysis at volume
Nobody reads a week of measurement data until something breaks. An AI layer flags a parameter trending toward its limit before it crosses, and answers which station, which shift, which batch.
Faster test development
Drafting a sequence from the specification and generating the instrument-control code. The engineer validates every line; the model does the typing. Our largest measured gain so far.
Failure diagnosis
A failing measurement is correlated against history and the likely causes ranked with their evidence — component tolerance, fixture contact, calibration drift, or a real design limit.
Change-induced yield shifts
Sequence and limit-table versions are recorded on every run, so a drop in first-pass yield can be tied to the change that caused it. Most lines cannot ask this — the version was never recorded.
Coverage review
Reading a schematic, a netlist and the test plan together, and reporting what the plan does not cover — design-for-testability, applied to the test plan itself.
The data foundation is the prerequisite, not the AI. An AI layer reads the production result database — so a tester that stores only pass and fail gives it nothing to reason over, and that is the first thing worth fixing.
Customer Outcome
Customer outcome
Sasken’s production test solutions help customers move from development to volume manufacturing with product quality that holds as volumes grow. Customer benefits include:
Because every measurement is stored per unit and per batch, yield trends and field returns can be traced back to the measurement that passed them.
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