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Jan/Feb 2025
How Takaya Flying Probe Technology Fuels Microboard’s Success
By Michael L. Martel, Contributing Editor T
ransitioning to new testing technology often feels like a gamble, especially for an established electronic manufactur-
ing services (EMS) provider. For Microboard, an EMS company offering printed circuit board assembly (PCBA) and system integra- tion services in Seymour, Connecticut, adopt- ing Takaya’s flying probe technology more than two decades ago was a calculated risk that has paid off in efficiency, cost reduction, and quality assurance. The move not only transformed Microboard’s operations but also demonstrated the immense value flying probe testing brings to OEMs.
A Shift in Testing Traditional test methods, such as
bed-of-nails (BON) testers, relied heavily on fixtures that were expen- sive and time-consuming to produce. This approach posed challenges for high-mix product lines, where changes in design or engineering often required new fixtures, driving up costs and extending lead times. Micro board’s engineering team
began exploring alternatives and found their answer in Takaya’s Flying Probe technology. “We decided on Takaya’s technol-
ogy because of its accuracy,” recalls Jim Wasilewski, test engineering manager at Microboard. “With the advent of SMT, components were placed on both sides of the board, eliminating many test points. Flying Probe technology’s ability to target test points precisely and measure compo- nents accurately made it the perfect solu- tion.”
Microboard acquired its first Takaya fly-
ing probe system in 1999 and quickly real- ized the benefits. “That first system soon became two, then three. As production vol- umes grew, the cost of developing in-circuit tests skyrocketed, and customers began seek- ing alternatives. Flying Probe testing
Takaya’s flying probers are efficient, can reduce costs and boost QA.
you’re looking at recreating the entire fixture and program. With flying probe, we can spin up a program in three or four days at a frac- tion of the cost.” Unlike traditional methods, flying probe
testing does not require dedicated test points. “In-circuit tests depend on having test points, which are often removed during the design stage to save space,” Jim explains. “Flying Probe technology can test vias and through-hole components without needing additional points, streamlining the process.” This flexibility enables Microboard to handle high volumes efficiently, testing over 3,500
allowed us to meet these demands efficient- ly,” Jim explains.
Key Benefits of Flying Probe Testing Flying probe technology eliminates the
need for expensive fixtures and reduces costs associated with engineering change orders (ECOs). “Developing a bed-of-nails test can cost between $30,000 and $60,000 per board,” Jim notes. “If the design changes,
work orders per month. Flying probe systems excel at identify-
ing manufacturing defects and verifying functionality. “Our test philosophy ensures every board goes through impedance and power supply checks,” says Lonny Harris, an engineer at Microboard. “Takaya’s CNET and DNET capabilities allow us to reduce the number of probe marks on components while maintaining high coverage.” By integrating flying probe testing early in the process, Microboard ensures accurate placement and functionality, reinforcing its repu- tation for quality and reliability.
A Measure of Quality Microboard’s adoption of Takaya’s
flying probe technology has elevated its quality assurance processes. “Flying probe testing is the first time in our pro- duction line where measurements are physically verified,” Jim states. “It’s a critical step before boards are depanel- ized, allowing for rework if necessary. This process mimics the test plan of any bed-of-nails system but with greater flexibility and cost-effectiveness.” The flexibility of flying probe testing
has also been a key driver of customer satisfaction. “Many of our customers come from bed-of-nails test houses,” Jim notes. “When we tell them we can adapt to design changes quickly and cost-effec-
tively, it’s a huge selling point.” After 20 years of leveraging their initial
investment in Takaya’s flying probe technol- ogy, Microboard saw the need to upgrade to the latest capability and completed a market assessment including Takaya’s competitors. Microboard made the decision to select Takaya’s latest technology and today oper- ates multiple Takaya APT-1400F-SL sys- tems, which includes the capability to test large form-factor boards. “We’ve stayed with Takaya for over 25 years because of their exceptional service and the minimal issues
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