TEST LABS: Tips for Choosing and Using Test Labs

June 2nd, 2005

Testing has become such a complicated affair in the automotive industry that it’s nearly impossible for a manufacturer or supplier to do all its own testing. For one thing, the company would have to make a huge investment in specialized test equipment and in the people needed to design and perform the tests.

That’s one reason many companies call on independent test labs to test automotive parts and systems. Because it’s their business to run tests for customers, independent test labs have invested in the necessary equipment and expertise. You can find test labs for nearly any kind of test including electronics tests, materials tests, environmental tests, electromagnetic compatibility (EMC) tests, powertrain tests, and so on.

While hiring a test lab to perform required testing is often rewarding, realize that doing so is not without risks and responsibilities. You’ll have to work with the lab before, during, and after the tests to ensure that you get the results you want. To help you do this, here are some tips.

1. Do your homework first.
When choosing a test lab, ask a lot of questions to make sure that the lab you choose can do the testing you require. Here’s your assignment:

• Request a tour of the lab’s facillites and talk to the lab personnel who will be working with you. Treat this tour as an interview. Check to see that the lab’s equipment is up to date and in calibration. Ask when the lab last ran the types of tests you need and find out what types of fixtures, if any, they will luse to run your test.
• Ensure that the lab has technicians who are qualified to set up and run your tests.
• Ensure that the lab has the appropriate accrediation.
• Ask for references. A good test lab can refer you to satisfied customers who can then give you more information abou tthe lab. Ask these customer’s if they were satisfied with the lab’s work, if they understood what the customer wanted to accomplish, and whether or not lab personnel asked questions about the company’s test specs. Finally, ask the customer if they would use the lab again.
• Ask for the lab’s confidentiality policy. You don’t want your test data getting into the hands of your competitors.

2. Contact several test labs.
Just as you would contact several contractors if you were putting an addition on your house, you should contact several test labs, giving each one a copy of your test specifications and asking for a quote. The information that the labs provide in response will help you decide which lab to hire. Include the following in your test spec:

• the type of vehicle or component you need tested,
• the number of vehicles or components the must test,
• the test standard, if applicable, that the test procedure must conform to,
• the test data that you expect the tests to generate, and
• the desired start and completion dates.

Also, make sure that the test labs understand why you need to conduct these tests so that they can help you develop the best possible test plan.

3. Contact test labs early.
It’s important to contact test labs early in the process. The reason for this is that test labs can help you design a successful test program, but only if you give them enough time to do so.

One way they can help you is by providing accurate estimates of test time and test costs. This information can help you develop an accurate project plan and budget, which will also help you keep on schedule.

Another way the lab can help is by alerting you to any special equipment that they might need to perform a test. To properly test an exhaust manifold, for example, you must supply an engine to which the manifold attaches.

Finally, the lab can help you deal with your customers. Auto companies, for example, may specify generic test specifications in their supplier contracts. The problem is that these specifications are not specific enough for particular tests. The test lab can help you take these contractual requirements and then give you the information you need to negotiate a test strategy with your customer.

4. Specify tests completely.
Specifying the test as completely as possible will help reduce misunderstanding that could cause delays or invalidate test results. When appropriate, make sure your test specifications refer to applicable SAE standards or company specifications. Conduct a joint review of the test specs with the lab before testing begins. The review will help ensure that you and the test lab are working towards the same goals.

You need to know why you’re doing the tests and how to specify the tests properly. You also need to know the technial aspects of the tests to determine if the lab can do the job properly and if it can properly analyze the results. The more you know about the tests, and the closer you are to the test process, the more likely it is that you will get good results.

5. Check lab accreditation.
Accreditation is one way to check whether or not a lab is qualified. Many test labs have achieved ISO 9000 accreditation. This means that they have a quality system in place and that they have documented their processes.

You may also want to require that your test lab comply with and be accredited to ISO/IEC/EN 17025-2005¹, “General requirements for the competence of testing and calibration laboratories.” ISO/IEC Guide 25 more directly addresses quality requirement for calibration and testing labs than does ISO 9000, and labs receive accreditation for various types of testing, including acoustics and vibration, calibration, chemical, electrical, environmental, mechanical, non-destructive testing (NDT), and thermal testing. Make sure that the lab not only has ISO/IEC Guide 25 accreditation, but is accredited for the types of testing you want them to do.

6. Recognize that “real time” exceeds test time.
Realize that a test’s real time–the amount of time that elapses between when a lab receives test specifications and when it delivers a test report–exceeds test time.

There are several reasons for this. First, a test lab will have to ensure that a customer has properly specified a test and that it has the people and equipment needed to perform the test properly. Second, the lab may have to schedule tests rather than starting them right away. The test lab probably serves many different customers, and those companies may be ahead of you on the lab schedule. Third, the test lab will need time to analyze the test results and prepare a test report.

To avoid missing milestones, include enough time in your project plan for all these activities. If you’re not sure how much time a lab will need, ask for a time estimate in advance.

7. Perform a “post-test” review.
Once a lab has performed a test and submitted test results, review the entire process. By asking the following questions, you’ll be able to improve the test process:

• Did the test meet its objectives? If not, was it because you specified the wrong test? Was the test performed incorrectly? Did you supply enough test samples?
• Was the test completed on time? If not, was it because of an unavoidable delay at the test lab? Were you late in supplying test samples or documentation the lab needed to run the test?
• How well did your company work with the test lab? Did you people cooperate with the test lab? Did the lab provide enough customer support? If not, why not?
• What worked well? Be sure to document what worked well so that you can take advantage of your experience next time you hire a test lab.

Reference

1. ISO/IEC/EN 17025-2005, “General requirements for the competence of testing and calibration laboratories,” American National Standards Institute (ANSI). 212-642-4980. www.ansi.org.

Entry Filed under: Test Labs