Method and apparatus for testing custom-configured software/hardware integration in a computer build-to-order manufacturing process

• US 6,543,047 B1
• Filed: 06/15/1999
• Issued: 04/01/2003
• Est. Priority Date: 06/15/1999
• Status: Expired due to Term

• Current Assignee: Dell USA LP (Dell Technologies Inc.)
• Original Assignee: Dell USA LP (Dell Technologies Inc.)
• Inventors: Maia, Paul J., Nix, W. D. Todd, Barajas, Gaston M., Vrhel, Thomas Jr.
• Primary Examiner(s): Morse, Gregory
• Assistant Examiner(s): Vo, Ted T.
• Application Number:
  US09/333,786
• Time in Patent Office: 1,386 Days
• Field of Search: 717/11, 717/1, 717/124, 717/177-178, 717/101-103, 717/121, 717/123, 717/126
• US Class Current: 717/121
• CPC Class Codes: G06F 11/3672 Test management
• CPC Class Codes: G06F 8/61 Installation

Abstract

A build-to-order manufacturing method for producing a custom configured computer system includes obtaining a customer order. Hardware for the custom configured computer system is assembled in accordance with the customer order. The assembled hardware is then tested using software tools and utilities. Next, software is downloaded to the computer system in accordance with the customer order, the software including an operating system (OS). Lastly, a fully integrated system test is performed, the fully integrated system test including the execution of an OS setup for fully integrating the hardware and software of the custom configured computer system and testing of the fully integrated hardware and software from the OS'"'"' perspective prior to shipment to a customer.

Claims

1. A build-to-order manufacturing method for producing a custom configured computer system comprising:

assembling hardware in accordance with a customer order;

testing the assembled hardware;

downloading software to the assembled hardware in accordance with the customer order, the software including an operating system; and

performing a fully integrated system test, the fully integrated system test including a) executing an operating system setup configured to fully integrate and test the hardware and software of the custom configured computer system from a perspective of the operating system prior to shipment to a customer and b) automatically executing, subsequent to the operating system setup, a software-based test module configured in accordance with the custom configured computer system being manufactured, being data driven, and having an input and an output, wherein the software-based test module input includes a system ID, a system configuration, a line of business, hardware components, software components, and expected deviations, the software-based test module responsive to data at its input for performing a testing of the integration of hardware and software of the custom configured computer system and further being adapted to uncover a configuration or functionality issue unable to be detected by the operating system and which results in the occurrence of a system integration problem, the configuration or functionality issue including a presence of at least one of an erroneous hardware component, an erroneous software component, and an interoperability between two components, the software-based test module further providing a corresponding test results data at its output.

2. The method of claim 1, wherein the software-based test module includes a query of whether or not the operating system has detected any errors during execution of the operating system setup.

3. The method of claim 1, wherein

the system ID includes a serial number for identifying the particular computer system being manufactured,

the system configuration includes a listing of the hardware and software components of a customer order,

the line of business includes the particular base unit identification of a given line of business for a particular desktop or notebook model,

hardware components include those as ordered per the customer order,

software components include those as ordered per the customer order, and

expected deviations include prescribed deviations which can be expected for a particular type of computer system being manufactured.

4. The method of claim 1, wherein the software-based test module output includes confirmation of proper component operation, logging of a device tree for the custom configured computer system, and confirmation of proper drivers being installed in the custom configured computer system.

5. The method of claim 4, further including querying the software-based test module output to determine whether or not any errors were detected, and if errors, then performing a suitable error logging and signaling a hard fail, otherwise if no errors, then cleaning up the fully integrated system test software-based test module from the custom configured computer system and sealing the custom configured computer system.

6. The method of claim 1, wherein the software-based test module launches in response to the operating system reaching a operating system desktop condition.

7. The method of claim 1, wherein the fully integrated system test includes a query as to whether or not the computer system and all components tested okay, and

if the computer system and all components tested okay, then removing the fully integrated system test from the custom configured computer system, sealing the custom configured computer system and preparing the custom configured computer system for a subsequent customer first boot, and

if the computer system and all components did not test okay, then analyzing the custom configured computer system in accordance with errors uncovered by the fully integrated system test, and executing an appropriate corrective action.

8. A build-to-order manufacturing method for producing a custom configured computer system comprising:

assembling hardware in accordance with a customer order;

testing the assembled hardware;

downloading software to the assembled hardware in accordance with the customer order, the software including an operating system; and

performing a fully integrated system test, the fully integrated system test including the execution of an operating system setup for fully integrating and testing the hardware and software of the custom configured computer system from a perspective of the operating system prior to shipment to a customer and automatically executing subsequent to the operating system setup, a software-based test module in accordance with the custom configured computer system being manufactured, being data driven, and having an input and an output, wherein the software-based test module input includes a system ID, a system configuration, a line of business, hardware components, software components, and expected deviations, the software-based test module further for testing the integration of hardware and software of the custom configured computer system and being adapted to uncover a configuration or functionality issue unable to be detected by the operating system and which results in the occurrence of a system integration problem, the configuration or functionality issue including a presence of at least one of an erroneous hardware component, an erroneous software component, and an interoperability between two components, and the software-based test module output including confirmation of proper component operation, logging of a device tree for the custom configured computer system, and confirmation of proper drivers being installed in the custom configured computer system.

9. The method of claim 8, wherein

the system ID includes a serial number for identifying the particular computer system being manufactured, the system configuration includes a listing of the hardware and software components of a customer order, the line of business includes the particular base unit identification of a given line of business for a particular desktop or notebook model, hardware components include those as ordered per the customer order, software components include those as ordered per the customer order, and expected deviations include prescribed deviations which can be expected for a particular type of computer system being manufactured.

10. The method of claim 8, further including querying the software-based test module output to determine whether or not any errors were detected, and if errors, then performing a suitable error logging and signaling a hard fail, otherwise if no errors, then cleaning up of the fully integrated system test software-based test module from the custom configured computer system and sealing the custom configured computer system.

11. A computer system comprising:

a processor;

a memory; and

a storage device, the computer system having been manufactured in accordance with a build-to-order manufacturing method including assembling hardware in accordance with a customer order, testing the assembled hardware, downloading software to the assembled hardware in accordance with the customer order, the software including an operating system, and performing a fully integrated system test, the fully integrated system test including a) the execution of an operating system setup configured to fully integrate and test the hardware and software of the custom configured computer system from a perspective of the operating system prior to shipment to a customer and b) the automatic execution, subsequent to the operating system setup, a software-based test module configured in accordance with the custom configured computer system, being data driven, and having an input and an output, wherein the software-based test module input includes a system ID, a system configuration, a line of business, hardware components, software components, and expected deviations, the software-based test module further being responsive to data at its input for performing testing of the integration of hardware and software of the custom configured computer system and further being adapted to uncover a configuration or functionality issue unable to be detected by the operating system and which results in the occurrence of a system integration problem, the configuration or functionality issue including a presence of at least one of an erroneous hardware component, an erroneous software component, and an interoperability between two components, the software-based test module further providing a corresponding test results data at its output, wherein the system ID includes a serial number for identifying the particular computer system being manufactured, the system configuration includes a listing of the hardware and software components of a customer order, the line of business includes the particular base unit identification of a given line of business for a particular desktop or notebook model, hardware components include those as ordered per the customer order, software components include those as ordered per the customer order, and expected deviations include prescribed deviations which can be expected for a particular type of computer system being manufactured.

12. The computer system of claim 11, wherein the software-based test module includes a query of whether or not the operating system has detected any of errors during execution of the operating system setup.

13. The computer system of claim 11, wherein the software-based test module output includes confirmation of proper component operation, logging of a device tree for the custom configured computer system, and confirmation of proper drivers being installed in the custom configured computer system.

14. The computer system of claim 11, wherein the software-based test module launches upon the operating system reaching a operating system desktop condition.

15. A manufacturing method for producing a computer system comprising:

assembling hardware in accordance with an order;

testing the hardware;

downloading software to the assembled hardware in accordance with the order, the downloaded software including at least an operating system; and

executing a) an operating system setup for substantially integrating and testing the hardware and downloaded software from a perspective of the operating system prior to shipment to a customer and b) automatically executing, subsequent to the operating system setup, a software-based test module configured in accordance with the computer system being manufactured, being data driven, and having an input and an output, wherein the software-based test module input includes a system ID, a system configuration, a line of business, hardware components, software components, and expected deviations, the software-based test module being responsive to data at its input for performing a testing of the integration of hardware and downloaded software of the computer system and further being adapted to uncover a configuration or functionality issue unable to be detected by the operating system and which results in the occurrence of a system integration problem, the configuration or functionality issue including a presence of at least one of an erroneous hardware component, an erroneous software component, and an interoperability between two components, the software-based test module further providing corresponding test results data at its output.

16. The method of claim 15, wherein the software-based test module includes a query of whether or not the operating system has detected any errors during execution of the operating system setup.

17. The method of claim 15, wherein

the software-based test module input includes a system ID, a system configuration, a line of business, hardware components, software components, and expected deviations, wherein

the system ID includes a serial number for identifying the particular computer system being manufactured,

the system configuration includes a listing of the hardware and software components of a customer order,

the line of business includes the particular base unit identification of a given line of business for a particular desktop or notebook model,

hardware components include those as ordered per the customer order,

software components include those as ordered per the customer order, and

expected deviations include prescribed deviations which can be expected for a particular type of computer system being manufactured.

18. The method of claim 15, wherein the software-based test module output includes confirmation of proper component operation, logging of a device tree for the computer system, and confirmation of proper drivers being installed in the computer system.

19. The method of claim 18, further including querying the software-based test module output to determine whether or not any errors were detected, and responsive to a detection of errors, performing an error logging and signaling a hard fail, and responsive to a detection of no errors, clearing the integrated system test software-based test module from the computer system and sealing the computer system.

20. The method of claim 15, wherein the software-based test module launches in response to the operating system reaching an operating system desktop condition.

21. The method of claim 15, wherein the integrated system test includes a query as to whether or not the computer system and all components tested okay, and

in response to the computer system and all components testing okay, removing the integrated system test components from the computer system, sealing and preparing the computer system for a subsequent customer first boot, and

in response to the computer system and all components not testing okay, analyzing the computer system by a service technician in accordance with errors uncovered by the integrated system test, further for executing an appropriate corrective action.

22. A computer system comprising:

a processor;

a memory; and

a storage device, the computer system having been manufactured in accordance with a manufacturing method including assembling hardware in accordance with an order, testing the assembled hardware, downloading software to the assembled hardware in accordance with the order, the downloaded software including an operating system, and performing a substantially integrated system test, the integrated system test including a) executing an operating system setup for integrating and testing the hardware and downloaded software of the computer system from a perspective of the operating system prior to shipment to a customer and b) automatically executing, subsequent to the operating system setup, a software-based test module configured in accordance with the custom configured computer system, being data driven, and having an input and an output, wherein the software-based test module input includes a system ID, a system configuration, a line of business, hardware components, software components, and expected deviations, the software-based test module responsive to data at its input for performing the testing of the integration of hardware and downloaded software of the computer system and further being adapted to uncover a configuration or functionality issue unable to be detected by the operating system and which results in the occurrence of a system integration problem, the configuration or functionality issue including a presence of at least one of an erroneous hardware component, an erroneous software component, and an interoperability between two components, the software-based test module further providing a corresponding test results data on its output, wherein the system ID includes a serial number for identifying the particular computer system being manufactured, the system configuration includes a listing of the hardware and software components of a customer order, the line of business includes the particular base unit identification of a given line of business for a particular computer model, hardware components include those as ordered per the customer order, software components include those as ordered per the customer order, and expected deviations include deviations that can be expected for a particular type of computer system being manufactured.

23. The computer system of claim 22, wherein the software-based test module includes a query of whether or not the operating system has detected any errors during execution of the operating system setup.

24. The computer system of claim 22, wherein the software-based test module output includes confirmation of proper component operation, logging of a device tree for the computer system, and confirmation of proper drivers being installed in the computer system.

25. The computer system of claim 22, wherein the software-based test module launches in response to the operating system reaching a operating system desktop condition.