Series Production & 100% Testing
Series Production & 100% Testing: Ensuring Quality at Production Cycle Speed
Where every single product must meet defined quality requirements, testing itself becomes an integral part of series production. From the first test specimen to the millionth production part, we develop automated test systems that reliably capture, evaluate, and document relevant characteristics — precisely matched to your cycle time and production process.
100% Testing as an Integral Part of Your Series Production
100% testing places particular demands on the testing process: Every produced part must be evaluated according to the same criteria within the available cycle time. At the same time, the test must neither generate unnecessary rejects due to overly tight acceptance limits nor allow relevant defects to pass undetected.
The key questions are therefore which characteristics actually need to be tested on every single part, how reliably they can be measured within the available cycle time, and at which point in the production process testing provides the greatest benefit. Based on this, WSK Elektronik develops a testing concept tailored to your production process — as an in-line test, a final end-of-line test, or a combination of multiple test stations throughout the production line.
Cycle-Time-Optimized Testing and Automated Processes
To ensure that 100% testing can be integrated economically into series production, we consider the entire test cycle — from presenting the test specimen to the final pass/fail decision:
- Cycle-time-optimized test sequences: Measurements, signal processing, and evaluation are designed to achieve the required testing depth within the available production cycle time.
- Automated contacting and handling: Pneumatic, servo-driven, or, where required, robot-assisted systems position and contact the test specimens with a high degree of reproducibility.
- Variant-specific testing: Product variants can be identified automatically and assigned to the appropriate test plans, limit values, and parameters.
Reproducible Measurement Technology and Reliable Quality Assessment
When every production part is tested, the stability of the testing process directly affects scrap rates, rework, and defect escape. For this reason, we place particular emphasis on a measurement and testing architecture that remains stable and controllable over the long term:
- Stable measurement conditions: Mechanics, contacting, and measurement electronics are designed to minimize variation and deliver reproducible results.
- Reliable test decisions: Measurement ranges, tolerances, and limit values are tailored to the actual testing task in order to minimize misclassification.
- Traceable test data: Relevant measurement values and test results can be clearly assigned to the respective product and used for traceability or further process monitoring.
Your Path to 100% Testing in Series Production
The development of a production test system starts with the testing strategy. As part of our proven 6-step process for customized test systems, we place particular emphasis on three key aspects when implementing 100% testing:
1. Definition of Test Characteristics and Cycle Time
We analyze which characteristics need to be tested on every product and how much time is available for identification, contacting, measurement, and evaluation.
2. Development of the Automated Testing Process
We coordinate mechanics, measurement electronics, software, and interfaces to create a reproducible testing process within your series production environment.
3. Validation and Production Integration
We validate the complete system under realistic conditions and integrate the testing technology into your production environment, including pass/fail handling and data transfer.
Testing Requirements Already Defined?
Send us your cycle time, product data, and test specification for a technical feasibility assessment and cost estimate.
Still Need to Define Your Testing Strategy?
We support you in selecting suitable test characteristics and designing an economically efficient production testing process.
Scalable Testing Technology for Your Series Production
Product variants, production volumes, and quality requirements change over the lifecycle of a manufacturing process. That is why we rely on modular test architectures, flexible adapter concepts, and configurable test plans.
This allows existing systems to be adapted to new product generations or expanded with additional test stations. At the same time, standardized interfaces to line control systems, databases, and higher-level systems provide the foundation for end-to-end quality assurance.
Rely on 100% testing that does not operate alongside your production, but is integrated into the manufacturing process as a reliable component.
Frequently Asked Questions About Series Production and 100% Testing
With 100% testing, every manufactured part passes through a defined testing process. The specified quality, functional, or safety characteristics are evaluated. Which characteristics are tested depends on the product requirements and the overall testing strategy.
No. Depending on the process, testing can be carried out directly between individual manufacturing steps as in-line testing, at the end of production as end-of-line testing, or distributed across several test stations.
We optimize test sequences and data processing specifically for the production cycle. If required, individual tests can be performed in parallel, distributed across several stations, or carried out on multiple test specimens simultaneously.
Yes. Product variants can be identified, for example, via barcode, RFID, or information from MES or ERP systems. The system then automatically loads the appropriate test plan and the corresponding limit values.