Hardware Product Development Life Cycle

 

Embedded Hardware Product Design Life Cycle

Hardware product development is not an easy job. Either it is mechanical or electrical system based on complexity of design, it will be going to be more difficult.

Ken Olsen said – “Software comes from heaven when you have good hardware.”

In this article, I will discuss on top-level product development life cycle. Based on the domain – product design life cycle could vary from six to 2.5year like smart phone and IoT devices are fast industry with product development cycle short as six month, whereas automotive and military industry where there is more focus on reliability product life cycle time extend to 2.5yrs+. Every product has its own challenges in development.

Product life can be broken down into 3 major stages and subsections –

1.      Product definition (Concept/Idea)

a.      Scope of Project (List all must feature and good to have feature)

b.     Product Definition Requirement (PDR) and Specification

c.      System Architecture (Block Diagram)

d.     Design documentation and implementation

                                                  i.     High level design

1.      Critical component selection

a.      Decision Analysis and Resolution (DAR)

2.      Major electronic block circuit design

                                                ii.     Detailed level design

1.      Sub-circuits design

2.      Schematic capturing and PCB layouts

3.      Design analysis – simulation, calculation, WCCA.

2.      Product Development cycle –These phases of prototype development exist to minimize risks, defects, errors, bugs and design flaws before entering mass production. It is extremely important to identify and cope with these risks during the engineering design phase, otherwise producing and selling of faulty products would cost you a lot more in money and reputation.

a.      Stage 1: POC, Purpose is to demonstrate idea is feasible and implementable using evaluation kits and off the self-available devices

                                                  i.     Demonstration and Mock up

                                                ii.     Proof of Concept (POC) / Proof of technology (POT)

b.     Stage 2: Engineering Prototypes, product look-alike and work-like subsystem prototypes made of intended components to meet the functional requirements in the form factor as per your PRD. However, it could have some design not fully integrated due to production limitation or supply chain issues.

                                                  i.     Engineering Validation Test - EVT (EVT1.1, EVT1.2 … and other)

1.      At this stage all the engineering unit level test should be completed and each subsystem should be functional and working as intended.

2.      If any improvement is required, it should be fixed before moving to DVT

3.      Able to flash SW and device is able to run as intended in basic form.

4.      No electrical fault should be unre

c.      Stage 3: Manufacturing Prototypes

                                                  i.     Design Validation Test – DVT (DVT1.1, DVT1.2 … and other)

1.      DVT are similar to final look alike product

2.      Design should be tested and validated as per PDR and system level testing

3.      At this stage, you should carefully revise and consider features vs product quality/finish vs production and BOM cost vs production volume.

4.      Complete the necessary certifications for targeted markets: CE, EC, FCC, UL, RoHS, etc

5.      Develop and finalize boxing and packaging

6.      Commence to request RFQs from mass-producers and devise plans for logistics.

7.      Factory test process should be ready and all test limits are defined.

d.     Stage 4: Manufacturing Pilots (Assembly line and test benches validation), this is final design and limited production is planned to test capability for manufacturing and factory test.

                                                  i.     Product Validation Test– PVT

e.      Stage 5: Ramp up Pilots and Production, This is final design to be sold in market or used.

                                                  i.     Pre-production (PP) and  Mass Production (MP)

Design Stages

Timeline for each stage in mobile industry

3.      Product life cycle – Once product is design and validated as per scope of project. It goes on sale and have market life. This is broken into 4 stages –

Stage 1 – Introduction (Product Launch)

 Stage 2 – Growth (Due to market adaptability and consumer acceptance)

 Stage 3 – Maturity (Sale is no peak and product is running good)

 Stage 4 – Decline (Sales decline due to new products ramping up)