One bad test change can stop a production line. This supplier made that impossible.
Governed test-sequence management for a Fortune 500 automotive electronics supplier — 100+ end-of-line machines worldwide, every change approved, versioned, and traceable.
The Challenge
Test parameters changed locally, machine by machine — and each change halted production for ~30 minutes. Approvals lived in email threads.
What We Built
A centralized Test Sequence Governance Portal modeling the full hierarchy — Plant → Machine → Model → Variant → Sequence → Hardware → Parameter.
The Stack
System Architecture
Underneath the governance layer sits a simple request path: an engineer's action in the browser reaches the physical machine in five hops, with one engine in the middle deciding exactly what to run.
Web portal
User initiates the requestAn engineer submits the request from the browser — no separate desktop client or plant-floor install required.
Backend API (REST)
Routes request via REST callThe request is authenticated and routed over a REST call to the service that knows how to handle it.
Context engine
Resolves intent, selects DLLThe context engine works out what the request actually means for that specific machine, then selects the correct native driver to carry it out.
LabVIEW DLL API
Native driver executes commandA native LabVIEW driver — the same low-level interface plant engineers already trust — executes the command directly against the hardware.
Plant machines / robots
Machines execute physical changeThe physical machine or robot on the line carries out the change, with the result reflected back through the same governed portal.
Change Governance Workflow
Every edit — to a test sequence, a hardware parameter, or a model/variant record — moves through the same seven-step governed path before it ever reaches a machine. Nothing goes live on trust; every step is time-boxed and logged.
Engineer edits data
Sequence, hardware, model & variantAn engineer edits a test sequence, hardware parameter, or model/variant directly in the portal — there's no separate change-request form to fill out first. Read-only (Level 3) users can view but can't touch production data.
Ticket auto-created
Change captured for reviewThe edit doesn't go live. It's automatically wrapped in a ticket carrying the real before-and-after diff, routed to the right approval group, and visible on the live dashboard the moment it's created — no manual step, nothing hidden.
Approval group A1
5-min acknowledgment · 20-min SLACross-functional reviewers see the exact diff and have roughly 20 minutes to approve or reject it. Miss the SLA and the ticket auto-delegates to the next eligible approver — a change never just sits in someone's inbox.
Approval group A2
Second review, same SLAA second group reviews the same ticket under the same time-boxed rules. Every acknowledgment, decision, and any SLA breach or delegation is written to the audit trail as it happens.
Version compare
Before vs. after, side by sideOnce approved, the change is shown against the current live version — the real data diff, not a text description of it — so an approver's final sign-off is based on exactly what will change.
Mobile RSA auth
Offline 6-digit codeThe last gate before release: an offline mobile authenticator (built in Flutter) generates a 6-digit code tied to the approver's identity — built for plant floors where reliable internet can't be assumed.
Production release
New version, fully audit-loggedThe change goes live as a new version — prior versions are retained, never overwritten — with the complete record of who edited, who approved, any SLA breaches, and the RSA authorization event, ready for a functional-safety audit.
The Results
Numbers from production operation — not projections.
The governance portal turned chaos into control. We manage 100+ test machines remotely, with zero downtime and full traceability.Program StakeholderA leading Fortune 500 Automotive company
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