Testing is usually the most expensive, time-consuming and difficult activity during the development of engineering products and systems. Development testing must be performed to ensure that designs meet requirements for performance, safety, durability, reliability, statutory aspects, etc. Most manufactured items must be tested to ensure that they are correctly made. However, much of the testing that is performed in industry is based upon traditions, standards and procedures that do not provide the optimum balance of assurance versus cost and time. There is often pressure to reduce testing because of the high costs involved, without appreciation of the effects on performance, reliability. etc. Misperceptions are commonplace, particularly the idea that tests should not stress products in excess of their operating levels.

The main reason for this situation seems to be that engineers have not developed a consistent philosophy and methodology for testing. Testing is seldom taught as part of engineering curricula, and there are no books on the subject. Specialist areas are taught, for example fatigue testing to mechanical engineers and digital device testing to electronics engineers. However, a wide range is untaught, particularly multidisciplinary and systems aspects. Testing is not just an engineering issue. Because of the importance and magnitude of the economic and business aspects testing is an issue for management. Testing is perceived as a high cost activity, when it should be considered as a value-adding process.

The objective of this book is, therefore, to propose a philosophy of engineering test and to describe the necessary technologies and methods that will provide a foundation for all plans, methods and decisions related to testing of engineered products and systems. The book will help those who must manage and conduct this most difficult and uncertain task. It will also provide a text which can be used as the basis for teaching the principles of testing to all engineering students.

The book contains information on test organisations, standards, software, services, and equipment.

The contents are listed below.

This site provides lists, with links to Internet sites. These lists will be maintained, and readers are invited to contribute additions and corrections. The main lists are:

- Suppliers of test software test software

- Suppliers of test services, equipment and information test services

- Test-related standards, etc. standards

The book is closely linked to my book "Practical Reliability Engineering" (4th. edition 2002). For details visit PracticalReliability

Buy Test Engineering from your regular bookseller or direct from J.Wiley

For details of training based on the book, visit courses

BOOK CONTENTS

Preface

Why test? (causes of failure; reliability/durability; environments)

How to test? (test to succeed, test to fail?; accelerated test; testing components, systems, technologies, processes)

Analysis and simulation

Good and bad testing

Test economics

Managing the test programme

Introduction

Mechanical stress and fracture (fracture; fatigue; creep; vibration/shock)

Temperature effects

Wear

Corrosion

Humidity and condensation

Materials and components selection (metals, plastics, etc.)

3. ELECTRICAL AND ELECTRONICS STRESS, STRENGTH AND FAILURE

Introduction

Stress effects (current; voltage; temperature; power)

Component types and failure mechanisms (ICs; discrete semiconductors; passives; E-O; solder; cables/connectors; insulation)

Circuit and system aspects (distortion/jitter; timing/interference;intermittents, others)

Variation in engineering

Load-strength interference

Time-dependent variation

Multiple variations and statistical experiments (Including Taguchi)

Discrete variation

Confidence and significance

Reliability

Introduction

Quality function deployment

Design analysis methods (mathematical; mechanical (FEA, CFD, etc.); electrical/electronic (EDA, EM, etc.); systems)

Analysis methods for reliability and safety (FMEA, etc.)

Design analysis for processes ("Poka Yoke"; testability; etc.)

Software for design analysis

Limitations of design analysis

Using analysis results for test planning

6. DEVELOPMENT TESTING PRINCIPLES

Introduction

Functional testing

Testing for reliability and durability (accelerated test; highly accelerated life test (HALT))

Testing for variation: Taguchi method

Process testing

"Beta" testing

7. MATERIALS AND SYSTEMS TESTING

Materials (strength; hardness; toughness; wear; corrosion; etc.)

Assemblies and systems (temperature; vibration/shock,other conditions, combined environments, facilities for accelerated test)

System aspects (Power and rotating machinery, fluid systems, humans, large systems)

Data collection and analysis

Standard test methods

Test centres

Introduction

Circuit test principles (analog, digital)

Test equipment (manual, ATE)

Test data acquisition

Design for test (test capability; test software; scan design; built-in self-test (BIST))

Electronic component test (discretes, ICs; IC design for test)

EMI/EMC testing

Introduction

Software in engineering systems

Software errors (specification, design, code)

Preventing errors (specification, structure, style, checking, analysis, fault tolerance, etc.)

Languages

Analysis of software system design

Data reliability

Software testing

10. MANUFACTURING TEST

Introduction

Manufacturing test principles (Value added testing; test capability; test criteria; test stresses)

Manufacturing test economics

Inspection and measurement

Test methods (mechanical, electronics; systems)

Stress screening (ESS, HASS)

Electronics manufacturing test options and economics (board; assembly; integrating stress screening; economics)

Testing electronic components

Statistical process control and acceptance sampling

11. TESTING IN SERVICE

Introduction

In-service test economics

Test schedules

Mechanical and systems

Electronic and electrical (built-in test; "no fault found")

Software

Reliability centred maintenance

Stress screening of repaired items

Calibration

Introduction

Failure reporting, analysis, and corrective action system (FRACAS)

Failure data analysis: the "7 tools"

Acceptance sampling

Probability and hazard plotting

Time series analysis

Software for data collection and analysis

Reliability demonstration and growth measurement

General comments on data analysis

Sources of data

Introduction

Laws and regulations (safety and product liability)

Main regulatory agencies (USA, Europe)

Standards (international; NATO; USA; Europe; UK; etc.)

"Generic" standards (ISO9000; IEC60300; ISO/IEC61508)

Industry/technology standards (aviation/aerospace; automotive; other)

Conclusions (advice, guidance)

Introduction

Organisation and responsibilities (test departmen, design)

Procedures for test

The development test programme (what, how many to test?; system levels; purchased items; allocations; methods; economics; external facilities; regulations and standards)

The project test plan

Manufacturing and maintenance

Training and education for test

The future of test (virtual test; intelligent CAE; Internet; new hardware, test education)

Conclusions

1. Definitions and acronyms
2. Testing regulations and standards
3. Development test plan example
4. Production test plan example