As the electronics sector has evolved, so have the industry’s testing methods. Rising production and product functionality demands mean similarly higher standards for their quality assurance processes. Modular test systems are an increasingly valuable solution amid these trends.

A modular testing solution, as its name implies, has built-in support for multiple tools, test types and components. Operators can switch out instruments as needed for unique products or adjust the machine for a different process without complex changeovers or new equipment. This modularity has several key benefits for modern electronics manufacturers.

Flexibility

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The primary advantage of modular test systems is their flexibility. East and Southeast Asia account for 68.4% of all electronics exports globally. With so many devices relying on this area, Asian manufacturers must provide a diverse product range, requiring equal diversity in production and testing methods.

Conventional, non-modular quality assurance solutions quickly lead to excessive costs and time loss in the face of such a demand for flexibility. Facilities must either run multiple separate machine types or stop work lines for tool changeovers. Modular alternatives remove these barriers.

A single modular system can work with several types of devices and workflows.

Scalability

Similarly, modular testing provides increased scalability. Many electronics manufacturers today face a rising need to scale up quickly. Taiwan Semiconductor Manufacturing Company (TSMC) alone saw demand for products grow three times over in one year, highlighting how much growth the industry may expect in the future.

In addition to supporting fast changeovers in tool types, modular solutions can adjust their capacity quickly. Production lines using the equipment can then increase their output without time-consuming, disruptive upgrades.

Scaling up in minimal time is key to meeting today’s market demands. However, it also supports downscaling if necessary amid unforeseen shifts in the future. In either case, a modular system minimises losses and maximises returns when a manufacturer must adapt.

Cost Efficiency

The added flexibility and scalability of a modular test solution means manufacturers can enjoy higher cost-efficiency, too. As electronics have grown more sophisticated, testing equipment has become increasingly costly, thanks to its complexity. Modularity lowers those expenses in a few ways.

Most notably, a modular system means fewer components a facility must purchase to meet the same diversity of tests. While various products may require different instrumentation, the line can still use the same equipment chassis, backplate and software.

However, the industry will likely see a shift towards more T&M equipment receiving iterative software releases and updates as more manufacturers adapt to the increased popularity of digital equipment.

Fortunately, modularity also lowers ongoing expenses through its flexibility. Faster changeovers mean less disruption to the workflow, leading to fewer losses from downtime. As a result, the testing process itself improves the bottom line over time.

Usability

Electronics companies should also consider the user-friendliness of their quality assurance methods. Surging demand amid broader workforce challenges has left many businesses needing more trained people for testing, which can be difficult in a competitive environment. Modularity can help by making these processes easier to manage.

Because a single modular solution can serve multiple needs, employees must only learn how to use one device. Even if the worker lacks familiarity with a given system, it’s easier to become accustomed to managing one flexible system than needing to learn three or more.

As the bar for employee training and experience falls, it becomes easier for electronics manufacturers to scale up their workforce. Finding qualified workers is not as significant a challenge, and usage errors become less frequent.

Comprehensive Testing

It’s also worth considering how a modular testing system can offer higher confidence in a product’s quality. Conventional alternatives must often select a single test method that suits a target use case the best or increase costs by performing multiple disjointed trials. Modularity provides a balance between comprehensive quality assurance and efficiency.

With a modular approach, manufacturers can test multiple aspects of a product without disruptive changeovers or various machines. Taking this route means offering greater assurance that a device meets expectations without excessive increases in production times or costs.

Balancing testing comprehensiveness with costs is key in today’s market. Experts say the average price-per-unit in the global electronics industry will increase by 6.1% between 2024 and 2029. As prices keep climbing, customers will expect greater functionality to justify them, and modular testing meets both needs.

Best Practices When Deploying Modular Test Systems

As with any upgrade, modular testing solutions require attention to a few best practices for manufacturers to experience these benefits in full. First, it’s important to understand that “modularity” looks different between specific systems. Not all modular equipment will feature the same versatility or support the same types of workflows.

Considering how the electronics market is becoming increasingly fragmented, organizations must focus on their unique niches. Facilities should look for systems that support their current and expected future testing requirements, which may not always be the most overall flexible solution. Paying a higher price for a machine because it offers testing types ill-suited for the product in question does little for the company’s bottom line.

Versatility alone is not the only factor to consider, either. Equipment that serves multiple needs but to varying degrees of accuracy may not produce any meaningful improvements. Manufacturers should look for options with consistent accuracy and repeatability metrics across all supported testing types.

Ongoing maintenance is another critical usage concern. Modular test systems are most beneficial when they work for longer periods, as many of their benefits are small by themselves but add up over time. Consequently, facilities must implement thorough preventive maintenance plans to keep such equipment in top condition for as long as possible.

The Future of Electronics Testing is Modular

The electronics industry is growing, and not just in terms of its sales volume. Expectations around lead times, device functionality and costs are also rising. Adaptability is key to keeping up with these changes, and modular testing provides just that.

Modular test solutions are not the perfect answer to all a manufacturer’s problems, but they do enable higher flexibility, scalability, cost efficiency, quality assurance and usability. Capitalizing on such advantages today may be critical in succeeding tomorrow.

By: DocMemory
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