Getting the Most Out of Design for Testability

Verifying product performance through testing is critical, but can become costly and time-consuming if not designed for upfront. DFT focuses on enabling effective testing of products throughout development and manufacturing.

DFX, or Design for X, refers to a systematic approach to designing products and processes to achieve specific objectives or characteristics. The "X" represents various targets like manufacturability, reliability, usability, etc. DFX helps companies optimize their products across the entire product lifecycle.

DFX represents a holistic approach to product development that optimizes the design against multiple objectives. At Boston Engineering, DFX is a core part of our product development process. We focus on several key DFX areas that align with our expertise:

• Design for Manufacturability (DFM)
• Design for Assembly (DFA)
• Design for Cost (DFC)
• Design for Testability (DFT)
• Design for Reliability (DFR)
• Design for Serviceability/Maintainability (DFS)
• Design for Usability (DFU)
• Design for Modularity (DFMo)

Learn more about Design for X (DFX) at Boston engineering: Boston Engineering Design for X

Here is an introduction to Design for Testability (DFT):

Design for Testability involves anticipatory development to design products with testing in mind. By designing for testability, companies can optimize test coverage while minimizing cost and time to market.

Key DFT principles include:

•    Incorporating test points and interfaces on electronic modules
•    Designing mechanical assemblies for easy access and fixturing
•    Defining critical test parameters and tolerances early
•    Utilizing modeling and simulation for virtual testing
•    Specifying standardized tests leveraging industry best practices
•    Designing products for automated testing and data collection

Example Projects:

•    Developing a diagnostic self-test routine for a medical device, reducing external test time by 70%
•    Implementing common test fixtures and methods for an electronic product family, cutting fixture costs by millions

Where Problems Arise

Insufficient DFT leads to issues like:

•    Unable to fully validate product performance due to limited visibility
•    Excessive manual testing time and cost
•    Custom test fixtures needed for low-volume products
•    Scrap and rework due to manufacturing defects
•    Extended test development time delaying new product launch

Expert DFT analysis early in design could prevent these pitfalls.

DFT experts like Boston Engineering provide:

•    Proven DFT methods tailored to your specific product line
•    Knowledge of the latest testing technologies and tools
•    Skills to quantify tradeoffs on test approaches and diagnostic capabilities
•    Abilities to define effective test requirements and strategies
•    Insight on virtual modeling and simulation to reduce physical testing

 Understanding the Importance of a DFX approach

Applying Design for X (DFX) methodologies upfront in product development optimizes the entire lifecycle by improving manufacturability, testability, reliability, usability, and other critical characteristics. This avoids costly redesigns later on, facilitates high-quality products that satisfy customers, reduces manufacturing and service costs, and supports flexibility through modularity and platforms. The holistic perspective of DFX drives efficient, cost-effective delivery of successful products that provide competitive advantage. Investing in DFX early pays dividends across the entire product lifespan.

Do you offer training on DFX for engineering teams?

Education is critical to effectively implement DFX principles. We provide training tailored to your engineers’ roles and product lines. This includes overall DFX methodology, deep dives into specific disciplines like design for reliability or manufacturability, and practical application workshops. Our hands-on approach combines real-world examples and case studies with tutorials on leading DFX software tools. The goal is building organizational DFX expertise and establishing repeatable processes that endure beyond individual projects. Investing in DFX knowledge pays dividends across your entire product portfolio.

Ready to Begin your next DFX Project? 

Impossible Challenge? Try Us. 

Selecting a partner to help you complete your design project is a valuable option to reduce project duration and save money.    

The Boston Engineering product development system encompasses DFX to ensure a smooth product launch and success in the marketplace.  Boston Engineering has DFX knowledge and experience to address aspects and values of a product such as manufacturability, test, reliability, safety, serviceability, cost, and compliance with industry standards and government regulations.