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Project Experience

  • Web Server & Content Creation

    Problem: Test Engineering department had difficulties communicating vital information to all shifted support personnel in a 24/7 manufacturing environment. Access to documentation and drawings needed to be provided for rapid access in a fast paced production environment.

    Solution: Obtained an Hewlett Packard Proliant ML350Server to host various services needed to support production operations. The server was configured to use the Windows 2000 Advance Server operating system. Five SCSI drives were configured as 2 RAID level 1 (OS) and 3 RAID level 3 (Data). Initially the server was configured to use Apache as the HTTP Server. However this was soon changed to IIS Internet Information Services) due to need to have the server act as the SUS (Software Update Server) Server for the automated test stations on the production floor.

    Used VBScript, HTML and PHP to create web pages that offered dynamic web content. Provided a web application that linked to a MYSQL database that stored information concerning test adapter inventory and capital asset movement. Within the same year a discussion forum was provided through the use of PHP bulletin board to facilitate discussions on production testing issues.

  • Service Packs and Security Updates

    Problem: The automated testing systems (ATEs) use Windows as their OS software. These PC based systems operate on a sub-domain separate from the main corporate domain. Many of the standard corporate workstation configurations could not be used due to their negative effect on the testing environment.

    Solution: Windows service packs and security updates needed to be installed in the 300+ computers that control the production test stations. The recently added departmental web server was altered to add the ability to act as the SUS Server. This included making changes such as removing Apache (SUS requires IIS) and installing and configuring IIS. Once the the SUS server was configured then the 300+ client machines need to be configured. This was accomplished by making various registry changes via a script that runs daily that helps maintain the integrity of the hard drive configuration on each of the test systems.

  • Server Backup and Recovery

    Problem: Once the departmental server was put into service many uses for it became apparent. Quite soon it became a critical element for normal operations. It hosts an Oracle database, MYSQL database, PKD-1 Security Dongle, PDMS Uploader and the Test Engineering Web pages.

    Solution: Order a DAT Backup Drive to fit in the expansion slot of the server. Devised a backup plan that would provide the fastest data restoration with the fewest number of tapes. Used HP StorageWorks to schedule a full backup on Sunday night and then Differentials on the other nights of the week.


  • RF Calibration Procedure

Problem:  Production reports high yield loss due to high failure rate of TX power measurements of cellular phone engines.  TX power reading do not agree between two independent test stages.  Large amounts of time is spent retuning product and yield targets are not being met.

Solution: The root cause of the problem stems from three sources.  First, manufacturing test technicians have not be trainedd properly on working with RF systems.  A course was design and administered to train the staff on how to make and repair RF cables with SMA, N and BNC style connectors.  Also a clearly defined process is produced that used an RF source ( HP8657B RF Signal Generator) and Measuring device (HP437B Power Meter).  Technicians are taught when to re-calibrate the TX and RX paths such as when changing an RF Switch or disconnecting RF cabling to ATE.  In edition to the afore mentioned actions an aggressive maintenance program was instituted that included cleaning of RF test points, recalibration and torque of RF connections within the RF measurement path.

As a side benefit, a new way was discovered to tune and retune the cellular transceivers in a much shorter time thus increasing production line volume capability.  Instead of taking the DAC tuning values from a default value of "0" for each of the power levels it was found that the preset default values could be set to a level that reflected the average setting.

  • Audio Path Measurements


  • VCTXO Tuning


  • Custom Labeling and Barcode Technology

Problem: Inventory has Sales Packs of product with no demand.  Need to be able to convert to a Sales Pack with demand for a different sales region in Latin America.  Rework location for this region does not have data necessary to do label reprints of “Gift Boxes” and “Master Cartons”.  Business Infrastructure team estimates three to four days to work on getting systems ready with the data necessary to reprint labels with corrected data fields (EAN Number, Sales Order, SW ID, SKU, Etc).  This requires too many man hours and timeline for this this process does not fit with demand to move inventory.

 Solution: Re-Flash product to current firmware level as required by customer.  Use BarTender Bar-coding Software to reproduce the label as close as possible to the original.  This involves the installation of proprietary fonts into development environment.  Also it was necessary to locate various compliance symbols from the Internet to include on the label.  Research was done to find documentation to determine Barcode Types that were to be used for each label element.  For example…Code 39 for IMEI number, Code 128 for the product SKU and EAN 13 for the EAN number.

 The plan was to scan the old Gift Box label and import the IMEI (International Mobile Equipment Identification number) data into the label template created with BarTender.  However, there is no possibility to acquire the WLAN (Wireless Local Area Network) data from an existing barcode on the old label. So it is necessary to acquire the IMEI and WLAN   data pair from the Business Infrastructure team and place it into an Excel Spreadsheet.  An Excel embedded VBA script will need to be written to work in concert with BarTender to deliver the WLAN ID data to the BarTender generated label.

Label Screenshot


VBA Code Snippet


  • New Type Label w / 2D Barcode Needed for Product

Problem: Product located at logistics center needs to be relabeled and there is no time to return to factory in Finland

Solution : Used BarTender Barcode Labeling Software to produce a facsimile of the original factory label by importing in the IMEI number (International Mobile Equipment Identification number) at runtime via a 2D Handheld Scanner.  The WLAN ID (Wireless Local Area Network) text that corresponds to the IMEI can be populated to the label via a "lookup table" located in an Excel Spreadsheet.

N810 Type Label


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