Test fixture fulfillment process

This document outlines the complete fulfillment process for designing, manufacturing, and delivering bed-of-nails test fixtures to our customers.

Lead times by tier

Tier	Standard delivery	Expedited
Dev	2–3 weeks	1–2 days
Dev Pro	2–3 weeks	1–2 days
Production	6–8 weeks (2–3 weeks with proactive material stocking)	1–2 days when materials are pre-staged

Dev and Dev Pro fixtures are manufactured in-house from raw materials, which is what keeps their lead times short. Production fixture lead times are driven by sourced base equipment; proactive material stocking pulls them down to Dev Pro territory. See fixture tiers for how the tiers compare.

Process overview

The phases below apply to every fixture project. For Dev and Dev Pro orders the design and manufacturing phases compress substantially — the illustrative timeline shown here represents a complex Production-scale project.

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 is scheduled and the kickoff date is communicated to you.

Timeline: Immediate follow-up after PO; awaiting customer confirmation

Key Stakeholders: Sales team, Customer, Project Manager

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2. Kickoff

The project starts with full planning and a kickoff email so you know exactly who is working on your fixture and when to expect each phase.

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: First business day following customer confirmation and scheduling

Key Stakeholders: Project Manager, Engineering Team, Customer

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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

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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

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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

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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)

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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

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Communication and 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 durations below reflect a complex Production-scale project. Dev and Dev Pro projects move through the same phases on a compressed schedule — 2–3 weeks from PO to delivery (see Lead times by tier).

Phase	Typical Duration
Pre-kickoff	1-3 business days (awaiting customer confirmation)
Kickoff	1 day
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	Dev / Dev Pro: 2–3 weeks · Production: 6–8 weeks standard

Note: Timeline may vary based on fixture complexity, component availability, and customer responsiveness.