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A typical morning for our team – ensuring top quality

The day starts right

07:45 am, Augsburg, Germany.

Herbert Dolzer, a System Engineer in our Hardware Development Department arrives at the factory. The day is scheduled with some meetings, tests and review roundtables between him, the production teams and our quality assurance people.

08:00 am

After the first coffee (something every engineer has a very special relationship with), Herbert checks his e-mails straight away. One e-mail was about the T50 release for our PRIMERGY RX2540 M4, a system currently already being sold, which is undergoing a qualification test for the support of powerful NVIDIA GPUs to support use-cases for artificial intelligence.

Quoting feedback from Production, one of the quality engineers informed him about some minor issues with the mounting procedure for air ducts in the system. (Editor’s Note: those are the mostly transparent plastic elements within a server, which guides the airflow through the server). Herbert immediately takes his coffee mug and makes his way down to the Fujitsu climate test center to look at the problem in more detail.

It’s always more than one thing at a time

08:15 am, Meeting in the test center

Herbert’s colleague Thomas Meissle, System Engineer Hardware Development at Fujitsu, walks him through the running test: a fully wired server is sitting on the test table with sensors connected all over it. It looks quite chaotic, but the system runs under a load of 96% meaning everything is fine so far.

The temperature in the climate chamber is about 45°C, it feels like a hot day, except that the ocean is not close by. It appears that some minor hotspots have been found on the very powerful yet quite “hot” GPUs mounted in the back of the system.

In addition, Production finds the current air duct rather difficult and tedious to assemble. This affects not only production, but also maintenance throughout the life cycle of the system.

08:30 am

Herbert realizes the air duct design is good, but not good enough for such special cases with GPUs. Herbert and Thomas both agree, system development can be costly, but it is worth the money and pays off in the end.

The highest quality components, trusted partners and continuous measurement and improvements from engineering over testing and production all the way through to logistics are the basis for PRIMERGY system development. However, the power of knowledge and smart decision is nothing without control. Thomas and Herbert double-check the measured results against the simulations and complete the test for now.

Great teams support to the best

08:40 am

Luckily, the previous simulation produced the same results, so he could prepare upfront: he takes out the prototype of a 3D-printed air duct with an improved design. It is expected that it will not only be easier to mount, but it should also improve the airflow through the system.

09:00 am

The new air duct is mounted, the server is wired up to all sensors again, and load is applied to the system with the climate chambers’ temperature kept at 45°C. A single tap of the ENTER-key and measurement begins.

To ensure valid results, the system under test is once again “tortured” under extreme conditions.

Speaking of the measurement of our PRIMERGYs and other hardware, such as the ESPRIMOs or LIFEBOOKs: these systems have gone through several mechanical tests, a very intensive vibration test and electromagnetic compatibility tests to measure electronic discharge, radiated field emission tests, as well as conducted emission testing.

Quality assurance is a brilliant thing

11:00 am

The start of the quality management meeting, which is a very important source of information for Herbert. All phases of the product development process had been checked and the final T50 test (just prior to a system’s release) has been approved for another system, the PRIMERGY TX2550 M4 (to learn more, check out this blog <Link>).

A great achievement and another step forward. Just after the meeting, Herbert receives a short e-mail with the first measurements from the climate chamber. Things look great and the new air duct does a good job, in line with the previous simulation. However, testing is not over yet and the next PRIMERGY systems are waiting in line to get ready for market.

Happy quality engineer, happy customers

12:00 noon

Herbert is happy. Not only because it’s time for a well-deserved lunch break, but also because he and his teams have been able to fix one of the several things you cannot really test on the drawing board but that call for actual, comprehensive and rigorous testing.

We at Fujitsu do this for the sole purpose of perfect quality and minimum interference to preserve nature and humankind. Our mission to a greener society goes beyond clever thinking – we criticize, challenge and validate at every step throughout a products’ life cycle. This is to make sure that you have the right foundation on which to build your business.

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