AJOLLY Testing is supporting the industrialization of a new DOCSIS 3.1 modem design in Manaus - Brazil, focusing on cost reduction, WiFi and FEM optimization, and efficient production. Key actions include tester adaptation, test analysis, hardware diagnostics, and process improvement using TestStand and LitePoint tools. In Mexico, AJOLLY is also redeveloping a LabVIEW-based software for an automated fuse box press, implementing a DQMH architecture with optimized Ethernet/IP and database communication to boost performance and reliability.
In light of the continuous evolution of technology and the growing demands for competitiveness, AJOLLY Testing is assisting in the transition to a new DOCSIS 3.1 modem design. The main objective is to reduce production costs by redesigning the WiFi section and FEM modules, while maintaining high performance and an efficient industrialization process. Another project is the redevelopment of an automated fuse box assembly press machine for Yazaki, where AJOLLY Testing is reengineering the software to achieve better performance and reliability.
- The industrialization of this new DOCSIS 3.1 modem design brings several key technical challenges:
- 🛠️Adaptation of testers and scripts: Analysis of the new specifications and updates to the test sequences to ensure optimized validation (TestStand and LitePoint IQfact).
- 📊Support for the production pilot and test analysis: Data collection and processing to quickly detect anomalies and provide correction recommendations.
- 🧠Hardware failure detection and collaboration with R&D: Identification of production defects and efficient communication for rapid adjustments.
- 📈Process optimization and increased production: Improvements in test time and infrastructure to maximize production cadence without compromising quality.
- 📍Location: Manaus, Brazil.
- Redevelopment of an Automated Fuse Box Assembly Press Machine
- Existing System: LabVIEW-based software integrating PLC and computer control
- Issue: Machine is operational but fails to meet performance expectations; original supplier unable to deliver improvements
- AJOLLY Testing’s Solution:
- ⚙️Development of a new software using DQMH architecture
- 🧩Focus on modularity, maintainability, and robustness
- 🔗Optimization of Ethernet/IP communication
- 🗄️Improved database data handling
- 🧪Development of a Python-based PLC simulator for Ethernet/IP, replicating real use cases to closely match the production environment. This enables reliable validation, reduces on-site installation time, and increases deployment confidence
- 🚨Complete redesign of the error handling system, as the previous software reported no errors, which severely hindered diagnostics and maintenance
- 📍Location: Durango, Mexico.