Production Test & Fixtures

Manufacturing enablement delivered as artifacts—EOL functional test strategy, fixtures, test software, pass/fail criteria, and traceability-ready logs for controllers, BMS, and battery pack programs.

Define test coverage and acceptance criteria (what we test / what we don’t)
Fixture scope: mechanical jig, wiring harness, connectors, probes (program-defined)
Test software: scripts, parameter files, version control, station IDs
Logging & traceability: serial logic, station logs, pass/fail records (program-defined)
Manufacturing handoff: SOP, calibration/maintenance guidance, release checklist

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What this solution is (and is not)

This solution turns engineering prototypes into repeatable manufacturing tests. We define test coverage, build fixtures and test software, and deliver handoff artifacts. We do not replace your factory’s full production engineering team; we enable a controllable EOL workflow and traceability structure.

Where it fits in the program

Production test enablement should start before PVT. The right time to define EOL coverage is when interfaces and baselines are stable—otherwise factories ship “unknown behavior” downstream.

EVT: define what needs to be testable and what signals/logs must exist
DVT: validate coverage vs failure modes and tune acceptance criteria
PVT: freeze fixtures, scripts, station setup, and release checklist for ramp

Core deliverables (what you receive)

Deliverables are packaged to be integration-ready and version-controlled.

Test coverage definition: test items, conditions, instrumentation, and acceptance criteria
Fixture package: mechanical drawings, harness/pinout notes, connector definition (program-defined)
Test software package: scripts, parameter files, versioning rules, and station configuration
Pass/Fail rules: thresholds, tolerances, and re-test / rework flow (program-defined)
Logging & traceability: serial format, station IDs, log fields, and export format (program-defined)
Handoff package: SOP, calibration guidance, maintenance checklist, release notes

Typical test coverage (examples)

Controllers

Power stage functional checks (program-defined)
Sensor input sanity checks (program-defined)
Communication bring-up (CAN/UART) and message sanity
Fault code visibility and event log snapshot
Basic thermal/protection behavior sanity (program-defined)

BMS

Cell/temperature sense sanity checks (program-defined)
Protection logic behavior verification (program-defined)
CAN/UART diagnostics and fault reporting sanity
Event log export and traceability fields capture

Battery Packs

Wiring/pinout verification and connector checks
Basic functional verification aligned to pack architecture (program-defined)
Traceability fields capture and release checklist gating

Integration workflow (how we deliver)

Define scope: product type(s), target station(s), factory constraints, and throughput target
Agree on coverage: failure modes vs test items (what must be caught at EOL)
Lock interfaces: pinout, comms map, and baseline parameters (versioned)
Build fixtures and scripts; define pass/fail criteria and re-test flow
Pilot run: run samples, tune thresholds, validate log fields and traceability
Freeze release: fixture package + software package + SOP + maintenance checklist

Typical KPIs (program-defined)

First-pass yield (FPY) and re-test rate at EOL
Escape rate reduction (issues caught before shipment)
Station cycle time vs throughput target
Traceability completeness (serial, station logs, firmware/parameter version)
Debug time reduction using standardized logs

Inputs we need to scope the work

To propose an accurate fixture and test plan, we typically request:

Product type(s): controller / BMS / pack and target variants
Connector/pinout baseline and comms map (CAN/UART if applicable)
Failure mode priorities (what must be caught at EOL)
Factory constraints: station space, operators, throughput target
Data requirements: traceability fields and log retention expectations

Request a production test enablement proposal

Share your product type, factory constraints, and traceability requirements. We’ll respond with a structured proposal outline and next-step questions.