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ScanWorks reduces test costs and improves coverage for Vivace Networks' extremely complex boards

Vivace Networks makes very complex circuit boards with more than 9,000 nodes, ball grid array (BGA) and micro-BGA devices with more than 400 pins, 32 layers per board and numerous ASICs with as many as 1,247 pins. Vivace could achieve only 40 percent test coverage with its in-circuit test (ICT) systems. In addition, the ICT fixtures were expensive and they delayed a board's time-to-market because they were time consuming to produce.

"We knew we were going to have to use boundary scan and ICT in combination," explained Vivace's Director of Manufacturing Engineering, Dan Howley. "We started to sort through our designs to identify everything that could be tested by boundary scan and we discovered that we would be able to eliminate more than two-thirds of all the test points on our typical boards. And if you compare the cost of producing an ICT test fixture with all of the possible test points and the cost of a fixture with two-thirds fewer test points, you'd see that the cost differential is very significant. You save approximately $40,000 to $60,000 per fixture."

"On the basis of cost savings from ICT fixtures alone, to say nothing about our improved product quality, ScanWorks has paid for itself several times over and we've been using it for less than a year. In addition, there are hard-to-calculate savings, like the significant time and cost savings that ScanWorks makes possible during the fabrication of the printed circuit board itself. And there's no way we can figure out the reduced opportunity costs that we've enjoyed by bringing our products to market faster than we otherwise could have done. These cost savings are immeasurable, and they probably far exceed what we've saved on ICT fixtures."

Another reason why Vivace chose ScanWorks was its tight integration with the Agilent 3070 ICT systems. Because Vivace uses Agilent 3070 ICT systems in its manufacturing line, the firm could re-use ScanWorks boundary scan tests on the 3070, reducing ICT test development time. And as a start-up company, time-to-market is one of the most critical factors Vivace faces.

The company delivered its first system to a customer last year. It is developing broadband fiber optic Multi-Protocol Label Switching (MPLS) equipment for telecommunications transport applications over the public telephone network and the Internet. As a company moving out of its startup phase and one that is trying to stay a step ahead of potential competitors, Vivace places great emphasis on reducing the time it takes to ready new designs for the market.

"ScanWorks helps us bring up tests very quickly so that the design engineers don't have to wait long to see how a new design is going to function," said Senior Test Engineer Rick Harper. "ScanWorks has shaved as much as three or four weeks off of the prototype verification process for each board. This has really won over the design group. It's gotten to the point where the design engineers come to me early in the design process and ask me to help them put as much boundary-scan test into their designs as possible. They realize how valuable boundary scan is."

Harper came to Vivace from 3Com, where one of his responsibilities was to evaluate the various boundary-scan benchtop test systems. He chose ScanWorks.

"The versatility of ScanWorks is good. We can use it to test voltages as low as 1.8 V and that is very useful to us," Harper explained. "The ease-of-use of ScanWorks is also very good and the support people have been very helpful. Having local support was a big plus for us."

For more information about Vivace Networks, visit www.VivaceNetworks.com.