Automating Patch Cord Testing with the VIAVI MAP Platform
Manual testing is the enemy of high-volume manufacturing. This case study details how a leading fibre-optic cable manufacturer used the VIAVI MAP platform to increase throughput by 70% and eliminate human error.
Background
A leading fibre-optic cable manufacturer was expanding its production line to meet growing demand for high-speed network components. One critical area was the production and verification of single-mode and multi-mode patch cords used in data centres, telecom networks, and enterprise systems.
Each patch cord needed to be tested for insertion loss, return loss, and polarity before shipment, ensuring compliance with IEC and Telcordia standards. Manual testing, however, had become a bottleneck — slowing throughput, introducing human error, and creating challenges in maintaining consistent quality records.
To solve these issues, the manufacturer deployed the VIAVI MAP (Modular Automated Platform) as the foundation for a fully automated patch cord test system.
The Challenge: The Limits of Manual Testing
The company’s existing manual process relied on handheld optical loss test sets and visual polarity checks. Technicians manually connected cords, recorded loss values, and stored results in spreadsheets. This approach presented several problems:
- Inconsistent test results due to variable connector handling and cleaning.
- Low throughput, with each cord taking several minutes to test.
- Data management difficulties, as results had to be entered manually and verified later.
- Limited repeatability when scaling across shifts and operators.
The engineering team sought a solution that would automate optical measurements for high-volume patch cord testing and integrate directly with manufacturing databases.
The Solution: VIAVI MAP Platform
The manufacturer implemented a VIAVI MAP-230B chassis populated with Optical Switch and Power Meter modules, creating a scalable, multi-channel test station. The MAP platform’s modular design and Ethernet control interface made it ideal for integration with existing automated handling systems.
Each test station consisted of:
- A VIAVI MAP optical switch to route signals across multiple DUTs (Devices Under Test).
- A broadband light source and high-precision optical power meter for insertion loss measurement.
- Optional return loss test module for reflection performance.
- Software automation scripts that controlled switching, triggered measurements, and logged results automatically.
The setup enabled technicians to test multiple patch cords simultaneously. Once loaded into a fixture, the MAP system ran the full sequence — measuring both directions, verifying polarity, and storing results in a central database — without manual intervention.
The Results
After implementation, the manufacturer achieved dramatic improvements in efficiency and consistency:
- Test throughput increased by over 70%, enabling same-day verification for large orders.
- Measurement repeatability improved, with standard deviation in insertion loss reduced by more than 0.02 dB.
- Human handling errors and connector contamination were significantly reduced due to automated switching.
- Full traceability was established, as all test data was logged directly to the factory’s quality management system.
The system also allowed engineers to quickly adapt to new connector types (LC, SC, MPO) by reconfiguring the MAP modules rather than redesigning the entire setup — extending its lifespan and ROI.
Conclusion
By leveraging the VIAVI MAP Modular Automated Platform, the manufacturer transformed patch cord testing from a manual, labour-intensive process into a high-throughput, automated operation.
The MAP system’s precision, repeatability, and scalability delivered measurable gains in both productivity and product quality — ensuring every patch cord shipped met its optical performance specifications. Today, the facility can process thousands of patch cords per day with complete confidence in measurement accuracy, consistency, and compliance.
