Management of Test Utilization, Optimization, and Health through Real-Time Data

Abstract

Understanding what, where, and how test assets are being used has always been an arduous, if not, impossible task. With the advances in real time data, IoT (internet of Things), and big data, which are combined to build the foundation of Industry 4.0 (I4.0), we now have access to real-time actionable information at our finger tips. Not only can what, where, and how be obtained, barriers to intelligent systems and health/prognostics can be almost nonexistent. Organizations that have moved in this direction have seen increased utilization, uptime, flexibility, effectiveness and efficiency with dramatic decreases in cost of ownership, cost of test, ramp up time and diagnostics, and repair for both the systems and products built. Even secondary factors like system accuracy (or uncertainty), asset reuse, technology refresh, and gage R&R (repeatability and reproducibility) have shown positive impacts on overall test strategies and overall business results. Even with all these benefits, the barriers to entry to this new world can be massive. Not only are there the normal issues around change management, ingrained organizational culture, money and regulations, just as important are the changes needed in overall philosophy and operations of every part of a programs/product's life cycle. In the world of real-time data, there is no more throwing R&D designs over the proverbial wall to manufacturing - the wall is replaced with a two-way stream of real-time actionable data and feedback. It also breaks down all the walls between different operations in production, allowing data to be used for functions like; diagnostics and repair, allowing real-time measurement trending to measure uncertainty, optimizing assets to maximize utilization, monitoring instrument health, and removing the multitude of areas that manual processes cause “human” errors. These are just some of the benefits that come from developing, collecting and utilizing a real-time data strategy throughout a product's life cycle. A robust strategy benefits and strengthens virtually all parts of a business including development, production, support, marketing, supply chain, finance, and order fulfillment. This paper will explore the multi-faceted world of real-time data and how it relates to test. It will outline the short and long-term benefits, the cultural and strategic changes needed, the direct benefits to test strategies, its influence throughout the total product life cycle and its overall impact on cost, time and scope. In addition, it will lay out a practical way to get started on the journey to move forward on not only a strategy, but also an implementation plan.