Productizing test systems: How SMART bridges the gap between development and production

The first measurement works, and the prototype delivers reliable results. However, once a laboratory setup needs to become a solution for daily operation or repeatable production use, the real challenges often begin.

Individual measurement modules, temporary wiring, and organically evolved structures must be transformed into a reliable and maintainable system. Without a structured approach, complex signal paths, limited signal integrity, and missing documentation can make maintenance, modifications, and reproducible test results increasingly difficult.

This is exactly where SMART Productizing comes into play.

At SMART Testsolutions, productizing means transforming a measurement or test application into a technically qualified solution designed for long-term operation. The resulting system must fit the application, adapt to future requirements, and remain reliable, maintainable, and expandable throughout its lifecycle.

Whether the application involves current, voltage, or temperature measurement, a LoadBox, a Hardware-in-the-Loop (HiL) test bench, or a complex validation environment, every solution is tailored to the specific project requirements.

SMART Testsolutions brings more than 35 years of experience in automotive E/E validation, as well as applications involving batteries, fuel cells, and electrolyzers.

The added value starts at the earliest project stages. SMART reviews requirements and customer concepts, evaluates technical approaches, and assesses system architecture, component selection, signal routing, maintainability, and future manufacturing considerations.

Design-for-X principles such as manufacturability, assembly efficiency, testability, and cost effectiveness are incorporated from the concept phase onward. This approach helps reduce later modifications, service effort, and production costs while identifying technical risks at an early stage.

During early development phases, the priority is often obtaining results as quickly as possible. Pragmatic test setups serve their purpose initially but frequently reach their limits as requirements increase.

Insufficient documentation complicates maintenance, modifications become more time-consuming, and the importance of clearly defined interfaces and robust mechanical integration continues to grow.

SMART transforms such setups into professional test systems featuring structured signal and power distribution, transparent system architectures, and clearly defined interfaces. This enables repeatable manufacturing processes and controlled future modifications.

Reliable operation, maintenance, and future expansion require comprehensive technical documentation and clearly defined processes. Depending on the project, deliverables may include:

• Standards-compliant wiring lists and electrical schematics generated in ECAD systems
• 3D models, mechanical drawings, and installation concepts developed in CAD systems
• Hierarchical, production-ready bills of materials (BOMs) managed within ERP systems
• Manufacturing and assembly documentation with clearly defined workflows
• Test procedures, calibration concepts, and acceptance criteria
• Risk and safety assessments aligned with applicable standards
• Documented interfaces, spare-part information, and procurement data for future replacements

Supply chains and component availability are also assessed. Where appropriate, alternative sourcing strategies help mitigate risks associated with component obsolescence or supply shortages, protecting long-term investment security.

As a result, systems remain understandable and maintainable even when personnel or locations change. This improves operational reliability while reducing dependency on individual experts.

A key element of the SMART approach is its in-house cable manufacturing capability.

Rather than building error-prone point-to-point wiring directly inside the rack, cable harnesses are preassembled, verified, and integrated as modular subsystems. This simplifies assembly, maintenance, spare-part management, and system replication.

Particularly for customized and low-volume test systems, standardized connectors and repeatable manufacturing processes significantly reduce potential sources of error. The result is a system that can be reproduced consistently with the same level of quality.

Power supply modules, distribution systems, communication interfaces, and MCM-based measurement and stimulation modules can be combined flexibly to meet application-specific requirements.

SMART remains technology-neutral and vendor-independent. The objective is always to implement the solution that best fits the application.

Standardized plug-and-play designs allow individual components to be replaced or expanded without redesigning the overall architecture. For globally deployed test systems, this simplifies maintenance, spare-part management, and future modifications.