Case Study: Leading Wireless Receiver Manufacturing Company achieves 50x reduction in test risk and $1.5M annual savings with Keysight

Precision Power Level Accuracy Measurements Reduce Risk for Wireless Receiver Manufacturer

Leading Wireless Receiver Manufacturing Company, which designs receivers for aerospace and defense, faced production test risk because power level accuracy measurements had high measurement uncertainty. That uncertainty — traced to calibration performed with an older spectrum analyzer — led to false fails and false passes that threatened yield, warranty exposure and cost. The customer engaged Keysight (including Keysight Calibration Services and Keysight’s risk calculator) to evaluate and improve its measurement and calibration process.

Keysight found the customer’s signal generator had been calibrated against an older Keysight 8563E (≈ ±1.5 dB MU) and recommended modern calibration using newer instrumentation (e.g., Keysight E4440A PSA) and its risk calculator. By reducing measurement uncertainty to ±0.25 dB, Keysight’s solution improved true-pass rates (91.52% → 95.57%), cut false passes (0.48% → 0.01%) and false fails (6.39% → 2.08%), reduced false-pass volume from ~500 to <10 per 100,000 units (≈50× risk reduction), and produced an estimated $1.5M annual savings after switching to Keysight Calibration Services.