What to Consider When Making Your Product Ready for Manufacturing?

1. Product Concept, Feasibility and Architecture Finalization

At this stage the aim is to clearly identify the new product, based upon the organization’s strategy, marketing objective and customer demand. Generate and resolve queries to make the requirements more clear.

• In-depth requirements understanding – The basic idea of the product should be formatted as a document to map with the traceability matrix during product manufacturing transfer
• Feasibility study and analysis – It is important to identify unknown sections and validate with hardware and software simulators. Also, check the functional behavior with different analysis tools like Multisim, Proteus, LTspice, etc. to reduce time and cost of the design
• Selection of hardware and software platforms – There is no “one-size-fits-all” approach to select hardware and software for developing IoT solutions. For example, adopting standard-based hardware like microcontrollers can save time and expense in the early stages of development without sacrificing flexibility. However, one should choose such that both are compatible, integrable, portable, modular, have sufficient capacity, cost-efficient, risk-free, optimized, easy to use, high performance, power-efficient, secure and bug-free
• DFM, DFA and DFT aspects during the concept phase – It is one of the most important technical aspects to freeze the components, behavior, design flow and finalize architecture to make it easily manufacturable, assembled and tested based on the suggestions and guidelines

2. Product Design & Development

Indeed, nearly 80% of the cost of the manufactured product is determined by decisions made during the design and development processes and this decision-making often occurs during the first 20% of the design process in electronics manufacturing services. Thus, it is important to consider manufacturability in the early stage for product quality, reliability, testability, serviceability and customer values.

• Simulation – The hardware, firmware and mechanical simulators are the key elements to derive the system function based on the raw performance, timing accuracy and modeling
• Modular hardware, software co-design approach – This is one the best techniques to optimize the complex product and constraints such as power, performance, and cost
• Design verification and code validation at each stage – This approach will reduce the risk of design and help create the right product to meet the time to market. We at VOLANSYS, follow the schematic, layout, Gerber, mechanical CAD checklist tools to validate design and code to avoid mistakes during the design stage
• BOM review and optimization – It is very important to estimate the product cost of manufacturing during the design stage to avoid iteration, additional cost and time. This stage is generally taken care of as a part of the DFMA process we follow at VOLANSYS
• Review DFM, DFA and DFT aspects during design – The design approach is followed with specific guidelines and suggestions to meet the user expectations. The DFM covers verification of PADs and drilling optimization, stack-up details, fabrication material and tolerance, BOM alternates and optimization, parts evaluation, assessment and design review
  The DFA covers parts placement feasibility, assembly checklist, easy electromechanical fitment, IPC-based stencil requirements, smooth surface mount technology pick and place process, thermal profile selection, through holes guide and assemblyThe DFT covers test plans including EDVT, test points and breakpoints, test coverage, semi or full automation tools like python scripts, QT based-GUI, test Fixture requirements, etc.
• Mechanical aspects during design – Avoid or shorter overhangs and undercuts in parts design, draft corners in vertical surfaces of parts, minimum radius in internal corners, edges, achievable tolerance, deformations and internal stress, requirements of Test Jig fixture, Surface finishes like painting, texture, polish, etc.