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The Printed Circuit Assembler’s Guide to...Design for Test, A Practical Guide to Test and Inspection by Bert Horner, The Test Connection, Inc.
Chapter 1: The Importance of Test and Inspection in CCA and PCB Design
This chapter explains why test strategy must evolve alongside modern PCB complexity. The author explores ownership of test planning, manufacturing challenges, and the risks of neglecting testability.
Industry Evolution and Current Gaps
Over the last two to three decades, the electronics industry has experienced a significant transformation. Circuit card assembly (CCA) and printed circuit board (PCB) design have become highly automated and digitized, allowing for faster development and increased design reuse. Engineers can now easily build on existing, proven architectures.
Despite these advancements, one key area often falls behind: test and inspection. Although manufacturing and design tools have improved, test strategies frequently remain separate or reactive, developed only after the design is complete or the product is built. This gap can lead to missed chances to boost quality, cut costs, and speed up time to market.
Who Owns Test Strategy?
A fundamental question underlies the issue: who owns the test and inspection strategy?
In many organizations, test engineers often assume test strategy responsibilities too late in the product development process. By the time they are brought in, the PCB layout is often finalized, components are selected, and mechanical constraints are already established. This limits their ability to influence the design from a testability standpoint. Consequently, test engineers have to develop workarounds, such as creating test plans that address restricted access, probing dense areas, or relying heavily on software diagnostics. These compromises typically lead to incomplete test coverage, increased defect escape rates, and dependence on more expensive or complex testing methods. Moreover, late involvement heightens time-to-market pressures, forcing the rapid development of test fixtures and programs with little opportunity for iteration—often resulting in higher costs and a greater risk of field failures.
Test strategy ownership should be a shared responsibility across the product development team. Design engineers influence electrical and mechanical accessibility, while manufacturing planners understand process limitations and production flow.
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