I have been in a small factory today, they produced 4 kind of PCBs that all are simple analog boards, each month they produce 1000 of them. The problem is that till now, after mounting them almost 10% of them were damaged. So they prefer not to test each of them, as the cost of time did not worth for them. But now the percentage of damaged has increased and they are looking for a solution. I suggested to add some test point to the PCB and I will design a Tester. But the problem is something else, they say that they don't need a module tester. They need some thing that can tell them if they have to buy a series of component or not , for example they order 10,000 of capacitor , they need a tester to test specific number (I also have to suggest the number ) the capacitors and tell whether or not buy these batch or not , so basically I need to design a tester that can test these things : Resistors , Capacitors , Different kind of Diodes , Relays and LEDs?
So the questions are mainly these 2 thing :
For each device what are the best way that I can test them , even a document would be useful but , tips here is really appreciated because I can ask questions about.
Do we have to test all them before mounting or not?!! how can I get the efficient number for testing to get the best result? (if I have to change the question topic just let me know please)