Test Fixture Fulfillment Process
This document outlines the complete fulfillment process for designing, manufacturing, and delivering bed-of-nails test fixtures to our customers.
Process Overview
Detailed Process Steps
1. Pre-Kickoff
After a Purchase Order (PO) is submitted, the pre-kickoff phase ensures we have all the necessary information and customer approval before starting the project.
Activities:
Immediate Follow-up: Upon receiving a PO, we send a summary email to the customer containing:
- Complete fixture configuration details
- List of design files we will be using (PCB files, specifications, etc.)
- File format confirmation (ODB++, IPC-2581, or Gerber)
- Any special requirements or customizations
Customer Review & Confirmation: The customer must review and confirm that:
- The fixture configuration matches their requirements
- We have the correct and most current design files
- All specifications are accurate
Project Scheduling: Once confirmation is received, the project will be scheduled to start on the following Monday.
Timeline: Immediate follow-up after PO; awaiting customer confirmation
Key Stakeholders: Sales team, Customer, Project Manager
2. Kickoff
Project kickoffs are scheduled for Mondays to ensure a full week of productivity.
Activities:
Project Planning:
- Engineering project is fully planned
- All tasks are created and assigned
- Timeline and milestones are established
- Resources are allocated
Kickoff Email: A comprehensive kickoff email is sent to the customer containing:
- Project Lead: Name and contact information of the dedicated project lead
- Engineering Resources: Team members dedicated to the project and their roles
- Project Timeline: Estimated completion dates for each phase
- Communication Plan: How and when updates will be provided
- Next Steps: What to expect in the design phase
Timeline: Monday following customer confirmation
Key Stakeholders: Project Manager, Engineering Team, Customer
3. Design Phase
The engineering team develops the test fixture design based on the confirmed PCB files and specifications.
Activities:
- PCB Analysis: Import and analyze the customer's PCB design files
- Test Point Identification: Identify all test points and net connections
- Fixture Layout: Design the mechanical fixture layout including:
- Probe placement and alignment
- PCB mounting and support structures
- Connector and interface locations
- Vacuum or mechanical hold-down systems
- Electrical Design: Create wiring diagrams and electrical connections
- Component Selection: Select appropriate probes, connectors, and hardware
- Documentation: Generate design documentation and CAD files
Timeline: Varies based on fixture complexity (typically 1-3 weeks)
Key Stakeholders: Design Engineers, Project Lead
Deliverables:
- 3D CAD models
- Mechanical drawings
- Electrical schematics
- Bill of Materials (BOM)
- Probe list and specifications
4. Design Review
The completed design is reviewed with the customer to ensure it meets all requirements before manufacturing.
Activities:
Design Package Preparation: Compile all design documentation including:
- 3D renderings and CAD models
- Technical drawings
- Probe layout diagrams
- BOM and specifications
Customer Presentation: Present the design to the customer, highlighting:
- Test coverage and probe placement
- Fixture features and functionality
- Any deviations from standard design
- Timeline for manufacturing
Feedback & Revisions:
- Address customer questions and concerns
- Implement any requested changes
- Obtain formal design approval
Timeline: 3-5 business days for review; additional time if revisions are needed
Key Stakeholders: Project Lead, Design Engineers, Customer
Deliverables:
- Complete design package
- Customer approval sign-off
5. Manufacturing
Once the design is approved, the fixture enters the manufacturing phase.
Activities:
Material Procurement: Order all components, probes, and materials per the BOM
Mechanical Fabrication:
- CNC machining of fixture plates and components
- Surface finishing and treatment
- Quality inspection of machined parts
Assembly:
- Install probes and receptacles
- Wire electrical connections
- Mount connectors and interfaces
- Assemble mechanical components
Integration: Combine all subsystems into the complete fixture
Timeline: 2-4 weeks depending on complexity and component lead times
Key Stakeholders: Manufacturing Team, Procurement, Project Lead
Deliverables:
- Completed physical fixture
- Manufacturing documentation
- Assembly verification checklist
6. Quality Assurance
Every fixture undergoes rigorous quality assurance testing before shipment.
Activities:
Visual Inspection:
- Check for manufacturing defects
- Verify proper assembly
- Confirm component placement
Electrical Testing:
- Continuity testing of all test points
- Resistance measurements
- Short circuit detection
- Signal integrity verification
Functional Testing:
- Test with actual PCB (if available) or test board
- Verify all test points are accessible
- Check mechanical alignment and fit
- Validate connector interfaces
Documentation:
- Complete QA test reports
- Photograph fixture for records
- Create calibration certificates if applicable
Timeline: 1-3 business days
Key Stakeholders: QA Team, Test Engineers, Project Lead
Deliverables:
- QA test report
- Fixture certification
- Calibration certificates (if applicable)
7. Shipping
The completed and tested fixture is carefully packaged and shipped to the customer.
Activities:
Packaging:
- Protective packaging of the fixture
- Include all accessories and documentation
- Add handling instructions
Documentation Package:
- User manual and operation guide
- Maintenance instructions
- Wiring diagrams and schematics
- QA test reports
- Calibration certificates
- Spare parts list
Logistics:
- Coordinate shipping method with customer
- Arrange pickup with carrier
- Provide tracking information
- Insurance coverage
Customer Notification:
- Send shipping confirmation email
- Provide tracking number
- Include expected delivery date
- Schedule follow-up for receipt confirmation
Timeline: 1-2 business days after QA approval
Key Stakeholders: Shipping Coordinator, Project Lead, Customer
Deliverables:
- Packaged fixture
- Complete documentation package
- Tracking information
- Delivery confirmation
Communication & Support
Throughout the entire fulfillment process:
- Regular Updates: Customers receive weekly status updates via email
- Issue Escalation: Any delays or issues are communicated immediately
- Point of Contact: The assigned Project Lead is available for questions throughout the process
- Post-Delivery Support: Technical support is provided after delivery for setup and initial use
Timeline Summary
| Phase | Typical Duration |
|---|---|
| Pre-Kickoff | 1-3 business days (awaiting customer confirmation) |
| Kickoff | 1 day (Monday) |
| Design | 1-3 weeks |
| Design Review | 3-5 business days |
| Manufacturing | 2-4 weeks |
| Quality Assurance | 1-3 business days |
| Shipping | 1-2 business days + transit time |
| Total | 6-10 weeks from PO to delivery |
Note: Timeline may vary based on fixture complexity, component availability, and customer responsiveness.