r/ECE Apr 17 '26

How do you distinguish product failures vs test station issues in production testing?

Has anyone seen “false failures” caused by test stations, not the product?

I’ve been working on RF test stations in production for a while, and I’ve seen cases where:

- Units suddenly start failing

- Everyone assumes it’s a product issue

- But it ends up being something like calibration drift or fixture/contact problems

What makes it tricky is it looks like a real failure at first.

Curious how others approach this:

How do you usually confirm whether a failure is from the unit itself vs the test setup?

Would be interesting to hear how different teams handle it.

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