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Problem Statement

VVDN designed, developed and deployed an automated functional test jig to support high-volume production of Set-Top Boxes at the customer’s manufacturing site. The previous manual testing approach was not scalable and lacked the precision required for consistent high-volume output. As production scaled, the need for cost-effective, automated and throughput-optimized testing solutions became critical.

Customer Requirements

  • Replace manual testing with a fully automated, high-throughput system
  • Ensure consistent power-on and functional validation of the product
  • Minimize operator dependency and reduce human judgment errors
  • Improve yield, optimize floor space and meet a daily output target of 5000+ units

Key Challenges

  • Meeting stringent throughput and accuracy targets
  • Designing a compact and modular jig compatible with the existing manufacturing infrastructure
  • Testing multiple parameters, including audio, video and USB power
  • Ensuring test repeatability and ease of operation
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