Designing a Bespoke Programming Jig for Field Maintenance
Creating a dedicated test and configuration jig to support maintenance engineers and reduce downtime in the field
When developing a replacement product for a legacy system, it was essential to consider long-term serviceability from the outset. Our client needed a way for maintenance engineers to quickly test and configure plug-in modules, both during manufacture and once deployed in the field. To achieve this, we designed a bespoke programming and configuration jig as part of the overall solution.
Challenge
Our client required a replacement product that would remain fully compatible with an existing legacy system, without changes to the mechanical interfaces or external connections. As part of this, they needed a way for service engineers to quickly test, configure, and replace plug-in modules both during manufacture and in the field. The objective was to design a practical tool that supported long-term serviceability while remaining simple and reliable to use.
Project Overview
This project formed part of a wider product replacement programme, with the goal of supporting long-term maintenance and serviceability. The jig was developed as a dedicated tool for testing, programming and configuring modular plug-in boards both during manufacture and in the field to ensure consistent setup and minimise downtime.
Action
We designed and delivered a bespoke programming and configuration jig tailored to the client’s modular system. The jig included a custom PCB and a defined test protocol, making it possible to diagnose and configure modules quickly and consistently.
For the enclosure, we produced the first versions in-house using 3D printing to accelerate development. When additional jigs were required, production enclosures were manufactured by Prototype Projects, providing a professional finish with rapid turnaround.
OUTCOME
The programming jig enabled faster diagnostics and consistent configuration of modules, reducing downtime and making maintenance more efficient in both production and field environments. Incorporating the jig into the overall system design ensured that serviceability was considered from the start, providing the client with a reliable and sustainable support process.
TECHNOLOGIES & SERVICES INVOLVED
- Hardware Design
- PCB Design
- Mechanical Design
- 3D Printing
Hardware, PCB, Mechnical, 3D Printing, Automotive, Industrial
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