Streamlining PCBA Testing for High-Stakes Medical Devices

Background

A leading global medical technology company encountered escalating challenges in testing densely populated printed circuit board assemblies (PCBAs). As devices have become smaller and more complex, traditional testing methods have struggled to keep up with the demands of their high-reliability medical electronics.

The Challenge

The company needed a faster, more reliable way to test and validate their PCBAs, which often feature high component density, hidden solder joints (e.g., BGAs), and limited physical access for probes. Conventional in-circuit testing (ICT) and manual inspection were proving inefficient and error-prone, leading to delays in production and potential risks in device performance. The engineering team was under pressure to find a solution that could be implemented quickly without redesigning test platforms or adding costly external fixtures.

The Solution

ASSET InterTech stepped in with a precision-engineered solution rooted in boundary-scan (JTAG) and embedded instrumentation. The collaboration involved engineers and test managers from the company’s engineering and test management teams to architect a robust, scalable testing strategy.

Initial Diagnosis and Communication

The company’s test engineers reported issues with limited fault coverage and difficulty accessing critical nets and components.

ASSET InterTech began by analyzing the board architecture and identifying boundary-scan capable devices that could be leveraged for non-intrusive testing.

Technical Adjustments

ASSET recommended integrating ScanWorks Boundary-Scan Test (BST) into the company’s test flow.

The team restructured test actions to isolate interconnect faults and verify device integrity without relying on physical probes.

Development and Testing

ASSET’s development team provided tailored boundary-scan scripts and diagnostic tools.

After several iterations, the solution was refined to support parallel testing and programming of multiple boards, significantly improving throughput.

The Results

The deployment of ScanWorks boundary-scan technology transformed the company’s testing process. Debug time was slashed from 8.7 minutes to just 0.5 minutes per unit, enabling faster fault isolation and resolution. This optimization alone is projected to save the company $147,000 annually, based on throughput and labor cost modeling.

Test cycle times were reduced from hours to minutes, fixture costs were eliminated, and diagnostic precision was significantly enhanced. The result: accelerated production timelines, optimized resource utilization, and elevated reliability for life-critical medical devices.