Prototype to Product

73.3 MB·English

by  Alan Cohen

Copyright Page: ii
Table of Contents Page: v
Preface Page: xi
Why I Wrote This Book Page: xii
Who Should Read This Book? Page: xiv
Who Might Be Disappointed by This Book? Page: xiv
What’s Covered? What’s Not? Page: xv
How This Book Is Organized Page: xvi
A Word on Nomenclature Page: xvi
A Word on Jargon Page: xvii
Keeping in Touch Page: xvii
Safari® Books Online Page: xviii
How to Contact Us Page: xviii
Acknowledgments Page: xix
Chapter 1. The 11 Deadly Sins of Product Development Page: 1
The Fundamental Principle of Product Development Page: 2
The Vice of Laziness Page: 5
Deadly Sin #1: Putting Off “Serious” Testing Until the End of Development Page: 5
The Vice of Assumption Page: 6
Deadly Sin #2: Assuming That We Know What Users Want in a Product Page: 7
Deadly Sin #3: Assuming That Users Know What They Want in a Product Page: 8
The Vice of Fuzziness Page: 9
Deadly Sin #4: Lack of Comprehensive Requirements Page: 10
Deadly Sin #5: Lack of a Good Project Plan Page: 11
Deadly Sin #6: Not Assigning Responsibility Page: 12
The Vice of Cluelessness Page: 13
Deadly Sin #7: Not Addressing Regulations Page: 14
The Vice of Perfectionism Page: 15
Deadly Sin #8: The Sin of New-Feature-Itis Page: 16
Deadly Sin #9: Not Knowing When to Quit Polishing Page: 17
The Vice of Hubris Page: 18
Deadly Sin #10: Not Planning to Fail Page: 18
The Vice of Ego Page: 19
Deadly Sin #11: Developing Technology Rather Than Developing Products Page: 19
Final Thoughts Page: 20
Resources Page: 21
Chapter 2. Development Process Overview Page: 23
Don’t Panic! Page: 24
Product Development Life Cycle Overview Page: 24
A Great Idea Page: 25
Preliminary Planning: Does This Make Sense? Page: 26
Ballparking Page: 27
Setting Stakeholder Ground Rules Page: 28
First Reality Check Page: 29
Detailed Product Definition, a.k.a. Surprise Management Page: 31
Product Design Page: 33
Technical Risk Reduction Page: 34
Second Reality Check: Go or No Go? Page: 35
Detailed Development Page: 37
Prototyping Page: 38
Testing Page: 40
Purchasing Page: 42
Manufacturing Page: 43
Factory New Product Introduction Page: 43
Pilot Production Page: 44
Ongoing Production Page: 45
Final Thoughts Page: 46
Resources Page: 46
Chapter 3. How Electronic Products Are Manufactured Page: 47
Manufacturing Overview Page: 49
Supply Chain Page: 50
Building Circuits: PCB Assembly Page: 52
PCB Assembly: Solder Paste Application Page: 54
PCB Assembly: Placing Components Page: 56
PCB Assembly: Reflow Page: 61
PCB Assembly: Optical Inspection Page: 63
PCB Assembly: Hand Soldering and Assembly Page: 68
PCB Assembly: Cleaning Page: 70
PCB Assembly: Depaneling Page: 71
Test Page: 73
In-Circuit Test (ICT) Page: 74
Functional Test Page: 76
Burn-in testing Page: 77
Final Assembly Page: 78
Final Functional Test Page: 79
Packaging Page: 80
More, and Less Page: 80
How Many? Page: 80
Higher-Volume Production Page: 81
Lower-Volume Production Page: 82
The People Stuff: Factory Culture Page: 86
Final Thoughts Page: 87
Resources Page: 87
Factory Automation Page: 88
Factoryless (e.g., DIY) Manufacturing Page: 89
Chapter 4. Preliminary Planning: Can This Be a Success? Page: 91
Introducing MicroPed Page: 92
Why Does the World Need MicroPed? Page: 92
Marketing Requirements Page: 94
Target Markets Page: 95
Can It Make Money? Page: 96
A Quick Look at the Money Stuff Page: 96
Income Projections Page: 98
Cost of Goods Sold Page: 104
Gross Margin Page: 108
Can We Develop It? Page: 110
Identifying Unobtanium Page: 111
Go? No Go? Page: 112
Chapter 5. Detailed Product Definition Page: 115
Phase Overview Page: 115
Iteration Page: 117
The Road Ahead: An Overview Page: 120
So, What Will It Do? Specifying Our Product Page: 121
User Stories Page: 123
Use Cases Page: 123
Requirements Page: 126
From What, to How and Who Page: 129
Architecture Basics Page: 130
Top-Level MicroPed System Architecture Page: 134
More Architectures, and Design Page: 136
Technical Risk Reduction Page: 150
Updated COGS Estimate Page: 156
Go/No Go: Redux Page: 158
Resources Page: 159
Chapter 6. Detailed Development Page: 163
Detailed Development Process Page: 165
Software and Electronics: Chicken and Egg Page: 166
Electronics Page: 168
Software Page: 176
Mechanicals (Enclosures) Page: 183
System Integration Page: 200
Testing Page: 201
Verification Testing Page: 202
Requirements Traceability Page: 206
Manufacturing Testing (and Device Programming) Page: 207
Connections and Fixturing Page: 211
Moving into Manufacturing Page: 217
Final Thoughts Page: 219
Resources Page: 221
Electronics Page: 221
Software Page: 222
Injection Molding Page: 223
DFM & DFA Page: 223
Rapid Mechanical Prototyping Page: 224
Testing Page: 224
Moving into Manufacturing Page: 225
Chapter 7. Smart Platforms: Processors Page: 227
Low-End Microcontrollers Page: 228
8051 Class Page: 230
AVR Page: 230
PIC Page: 231
MSP430 Page: 231
Middling Microcontrollers/Processors Page: 231
Cortex-M: Microcontroller Profile Page: 232
Cortex-R: Real-Time Profile Page: 233
Cortex-A: Application Profile Page: 233
Big Iron: Desktop- and Server-Class Processors Page: 235
Other Hardware Platforms Page: 236
Systems on Modules (SOMs) Page: 236
Single-Board Computers (SBCs) Page: 240
DSP chips Page: 242
Programmable Logic Devices (PLDs) Page: 242
Final Thoughts Page: 245
Resources Page: 246
Chapter 8. Smart Platforms: Operating Systems Page: 249
Board Support Packages (BSPs) Page: 250
RTOSes Page: 251
Predictability Page: 251
RTOS licensing Page: 252
Middleweight OSes Page: 253
Embedded Linux Page: 253
Android Page: 258
Windows Embedded Page: 262
Boot Loaders Page: 263
Heavyweight OSes Page: 264
Advantages Page: 264
Disadvantages Page: 265
Final Thoughts Page: 267
Resources Page: 269
Chapter 9. Powering Our Product Page: 271
Batteries Page: 275
General Battery Characteristics Page: 276
Battery Chemistries Page: 279
Lithium Ion (Li-ion and LiPo) Page: 288
Wall Outlets: AC-to-DC Power Conversion Page: 304
DC-DC Power Conversion Page: 309
Linears and Switchers Page: 310
System-Level Power Design Page: 313
Supplying the Necessary Juice Page: 313
Minimizing Power Consumption Page: 315
Minimizing Cost and Complexity Page: 319
Final Thoughts Page: 322
Resources Page: 323
Chapter 10. Staying Safe: Regulations, Standards, Etc. Page: 325
Regulatory Fundamentals Page: 326
Process Overview Page: 327
Do these apply to little manufacturers like me? Page: 327
Laws, Regulations, Standards, and Other Regulatory Words Page: 328
Location Page: 333
Categories of Regulations Page: 334
Ambiguity in Regulations Page: 335
Conformance Testing and Certification Page: 336
Navigating US Regulations Page: 337
CPSC Page: 338
FCC Page: 340
European Regulations Page: 342
CE marking Page: 342
US Versus EU Page: 345
Finding the EU Regulations That Apply to Us Page: 346
Cradle to Grave: Safe Disposal Page: 347
Batteries at 35,000 Feet Page: 350
ITAR Page: 350
Quality Systems and ISO 9001 Page: 352
Final Thoughts Page: 355
Resources Page: 355
Voluntary Certifications Page: 355
EU Regulatory Framework Page: 356
ISO 9001 Page: 356
Chapter 11. Writing Requirements That Work Page: 357
Requirements Versus Goals Versus Specifications Page: 358
Why Requirements? Page: 359
The Case Against Requirements Page: 362
Customers don’t really know what they want until they actually have it Page: 364
Getting more-accurate information from users Page: 364
Technologists build what we ask them to build, not necessarily what we meant for them to build Page: 364
We gain important insights as the project progresses Page: 365
The world around us keeps changing Page: 366
Writing Good Requirements Page: 367
Careful: Requirements Are Design Constraints Page: 367
Requirements Should Be Testable Page: 368
Requirements Are Interface-Centric Page: 369
Positive Requirements Versus Lurking Requirements Page: 371
A Lurking Requirements Checklist Page: 372
Communicating Requirements Page: 374
Making Requirements Clearer Page: 376
Great Requirements Come from Great Participation Page: 378
Maintaining Requirements Page: 379
Requirements Management Software Page: 380
Final Thoughts Page: 381
Resources Page: 382
Chapter 12. Meta-Stuff: Project Planning and Infrastructure Page: 383
Project Planning Page: 384
Effort-Driven Project Planning Page: 388
Project Management Page: 393
Issue Tracking Page: 394
Document Control Page: 397
Change Management Page: 401
Final Thoughts Page: 402
Resources Page: 403
Index Page: 405
About the Author Page: 414
Colophon Page: 415