Product Development Methodology

Successful projects require proper planning and resources. A well constructed Product Plan ensure that your project is completed in an efficient and timely manner, that necessary resources are available when needed, and when deployed, your product meets the expectations of your customers. While all of the steps outlined below are unnecessary for every project, a strong formal methodology provides the framework for first-time success. 

Requirements Definition

Resource Planning

Design 

In Mechanical design, enclosure and mounting mechanisms are considered, components and suppliers are selected, CAD models/drawings are developed, and product industrial design & stylizing are finalized. Electrical design includes component/supplier selection, Bill of Materials management, analog prototyping/simulation, schematic capture, PCB layout, timing analysis, and signal integrity simulation. In the case of FPGA development, HDL code is written, models are developed, and the design is simulated. RoHS/Lead-Free and WEEE requirements are considered to ensure compliance with various compliance bodies. During Firmware design, in addition to source and device driver coding, usability guides, GUI screens, and menu navigation are completed and tested. System simulation, performed for large or complex projects, can frequently catch subtle design errors early in the development process. Additionally, design reviews are conducted prior to major milestone events such as PCB fabrication, Tooling construction, and release to Manufacturing.

iXL’s cross-functional development methodology ensures that information is conveyed across the entire product team. For example, feedback from Marketing requirements is used to drive the industrial design, PCB layout is driven by component placement and board dimensions provided from mechanical CAD modeling, key components are selected based upon firmware-driver requirements, thermal/volume restrictions, and electrical performance. This is an iterative process that ensures every element of the customer’s requirements are satisfied.

Once PCBs are fabricated and assembled, integration testing can begin in earnest. During development, a regression suite of module-level test routines should also be created.

Prototyping and Testing

Once the design is completed, alpha-level prototypes should be developed to thoroughly test the product. Mechanical parts and tooling are machined and full system integration can begin.

Testing should be conducted in as close to real-world conditions as possible. Preliminary testing under environmental conditions (temperature, humidity, altitude, shock/vibration, EMI/ESD, etc.) at this stage of the project, can uncover design deficiencies. HALT (Highly Accelerated Life Time) testing should be performed to identify and address potential field failure modes. Issued identified at this stage can be more easily corrected here leading to a robust product.

These initial prototypes can also be used for early customer feedback and collateral development.

Compliance Certification

Here, production-ready prototypes are tested for environmental compliance per CE and UL requirements and final HALT testing is completed. Other product and market dependent certifications and testing that may be necessary such as FCC, FDA, VCCI, and MIL-Spec, as well as compatibility conformance testing for peripheral buses (e.g., USB or Bluetooth) or operating systems (e.g., Microsoft).

A note of caution:  Testing is conducted through outside facilities and can be costly and time-consuming, particularly if good methodologies are lacking during the design phase. Proper planning and design practices will minimize impacts to budget and cost.

Marketing Development

Marketing Development includes the creation of collateral materials such as GUI artwork, Logos, User’s Manuals, Quick Start Guides, FAQ’s, installation procedures, and product packaging. Additionally, Localization considerations should be addressed. Once early prototypes are constructed, formal and informal focus groups can be held to gather early user feedback. If completed early enough, this important feedback can be incorporated into the design with minimal impact to schedule.

While outside the scope of our core competency, iXL will help to facilitate these processes by working directly with your staff, representatives, and external vendors.

Manufacturing Integration

Early and frequent communications with the manufacturing facility minimizes time-to-market delays and ensures that sufficient product is available for product launch. It is necessary to provide a complete manufacturing package including, test fixturing, test & training procedures. Frequently, an on-site visit to oversee initial training procedures and beta production runs, can shorten the production learning-curve, reduce scrap loss, and introduce manufacturing optimizations early in the production ramp. When considering international contract manufacturers (CMs), make allowance for time-zone differences and language barriers. Also consider issues such as component availability, supplier relationships, transportation and customs delays, as well as differing environmental compliance requirements.

Documentation

No project is complete without proper documentation. Documentation, such as a Design Specifications, Theory of Operations, Build Instructions, Bill of Materials, Approved Vendor List, Test Procedures, Design History File, CD Archive, etc.) facilitates better consultant-client communication ensuring that all of the project requirements have been satisfied. Additionally, proper documentation simplifies the Sustaining Engineering process, allowing others to maintain, service, and enhance the project as needs in the marketplace dictate.

Sustaining Engineering

To be successful in an ever-changing marketplace, an organization must position its products to meet demand. Sustaining Engineering is an important part of this process. By analyzing warrantee repair and customer returns data, the reliability and usability of current products can be determined. This data can be used to improve products and eliminate manufacturing defects. Additionally, this collected data can provide valuable insights into future product development.

As the design matures, lower-cost components and/or manufacturing alternatives can be incorporated to increase profit margins and improve manufacturing throughput. Finally, Sustaining Engineering efforts can extend and expand the life of existing products by adding new features, altering the industrial design, and/or address new markets. By leveraging prior engineering efforts, minor design modifications can yield low-cost, high-margin enhancements and product derivatives.