动态调整电子产线测试流程,省时90%还零漏检。
Quality-preserving Model for Electronics Production Quality Tests Reduction
- 离线找最小测试集,在线用强化学习实时切换测试方案。
- 功能测试省18.78%时间,终检省91.57%,漏检归零。
- 适合需要降本增效且怕漏检的高通量电子制造企业。
高批量电子生产中的测试流程通常在产品开发阶段固定,即使故障模式和工艺条件发生变化也照常执行。这虽保障了质量,却带来不必要的测试成本;现有数据驱动方法多优化静态测试子集,无法在线适应缺陷分布变化,也无法显式控制漏检风险。本文提出一种自适应测试选择框架:离线使用贪心集合覆盖法构建最低成本诊断测试集,线上采用汤普森采样多臂赌博机,依据滚动工艺稳定性信号在全测与简测间切换。在两个PCB组装环节(功能电路测试与产线终检)上验证,共覆盖28,000次板卡运行。离线分析发现零漏检的精简方案可使功能测试时间减少18.78%,终检减少91.57%。在真实概念漂移的时间验证中,静态缩减导致功能测试漏检110个缺陷,终检漏检8个;而自适应策略通过在不稳定时回退至完整覆盖,将漏检降至零。结果表明,在线学习可在不牺牲质量的前提下显著降低测试负担,为跨生产场景的自适应测试规划提供了可行路径,兼具经济与物流优化价值。
原文摘要 · Abstract (English)
Manufacturing test flows in high-volume electronics production are typically fixed during product development and executed unchanged on every unit, even as failure patterns and process conditions evolve. This protects quality, but it also imposes unnecessary test cost, while existing data-driven methods mostly optimize static test subsets and neither adapt online to changing defect distributions nor explicitly control escape risk. In this study, we present an adaptive test-selection framework that combines offline minimum-cost diagnostic subset construction using greedy set cover with an online Thompson-sampling multi-armed bandit that switches between full and reduced test plans using a rolling process-stability signal. We evaluate the framework on two printed circuit board assembly stages-Functional Circuit Test and End-of-Line test-covering 28,000 board runs. Offline analysis identified zero-escape reduced plans that cut test time by 18.78% in Functional Circuit Test and 91.57\% in End-of-Line testing. Under temporal validation with real concept drift, static reduction produced 110 escaped defects in Functional Circuit Test and 8 in End-of-Line, whereas the adaptive policy reduced escapes to zero by reverting to fuller coverage when instability emerged in practice. These results show that online learning can preserve manufacturing quality while reducing test burden, offering a practical route to adaptive test planning across production domains, and offering both economic and logistics improvement for companies.
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