Fundamentals Of The Electronic Product Design Process PDF

INDUSTRIAL ELECTRONICS A SHORT INTRODUCTION TO THE COURSE Dr Zeki KOCABIYIKOĞLU ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 1  INDUSTRIAL ELECTRONICS OUR LECTURES WİLL BE COVERED IN THE FOLLOWING ORDER PRODUCT DEVELOPMENT IN...

INDUSTRIAL ELECTRONICS A SHORT INTRODUCTION TO THE COURSE Dr Zeki KOCABIYIKOĞLU ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 1  INDUSTRIAL ELECTRONICS OUR LECTURES WİLL BE COVERED IN THE FOLLOWING ORDER PRODUCT DEVELOPMENT IN INDUSTRY PHOTOLITOGRAPHY AND SCREEN PRINTING THIN AND THICK FILM TECNOLOGIES PACKAGING, MNFG. SPECS OF ELECTRONIC COMPONENTS PASSIVE SOLID STATE DEVICES (RESISTORS AND CAPACITORS) ACTIVE SOLID STATE DEVICES (TRANSISTORS DIODES AND INTEGRATED CIRCUITS) PACKAGING CLEAN ROOMS 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 2  INDUSTRIAL ELECTRONICS SOLDER, FLUXES AND ENVIRONMENT PRINTED CIRCUIT BOARDS ELECTRICAL STRESS SCREENING ELECTRICAL TESTING 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 3  I. FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Dr Zeki KOCABIYIKOĞLU http://www.zkocabıyıkoğlu.etu.edu.tr 10/24/24 ELE 423 4  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Engineers usually have limited knowledge of manufacturing and marketing processes, their capabilities and limitations. This leads to designs which are –not needed in the market, –not on scheduled time, –not economically and tehnologically feasible to produce at all. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 5  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Designers limited knowledge of –materials, components, and their procurements, –manufacturing processes and testing, –marketing, field services/repair, reliability and quality causes design changes IN LATE STAGES OF THE product cycle to correct the deficiencies. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 6  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Such re-designings are costly in terms of –economy and –time to market It is because of these problems that the idea of “Concurrent Engineering” was formally put forward and used. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 7  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 8  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS CONCURRENT ENGINEERING is defined as: “A systematic approach to the integrated, concurrent design of products that considers –manufacturing and –support processes early in the design stages”. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 9  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS CONCURRENT ENGINEERING is intended to make the developpers, to consider all elements of the product life cycle from concept to disposal (from idea to obsolence)” CONCEPT DISPOSAL 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 10  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS REDESIGN REDESIGN CONCEPT DESIGN MANUFACTURING TEST REDESIGN SALES FIELD SERVICE CLASSICAL PRODUCT DEVELOPMENT (SERIAL ENGINEERING) 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 11  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Concurrent Engineering is a team effort Team is composed of specialists from the various activities. They all cooperate with their expertise, in the delivery of the product to the market at the rigth quality, rigth price and the rigth time 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 12  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Concurrent Engineering is information and communication intensive. There must be no barriers of communication amogst all parties. Top management must inform all contributors of any conceptual changes in the company attitude towards the new product. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 13  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS With concurrent engineering the design phase may take more time. However the overall time to market will be reduced because of the reduction in product re-designs. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 14 Example of design changes as a function of time for an American and Japanese automobile 15 Dr. Zeki U. KOCABIYIKOĞLU 15  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS In the absence of –realistic expectations, –good communication with the marketing people we end up with product having; –more functionality than necessary, –incorrect functionality 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 16  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Cost Considerations Proper design philosophy incorporates –economic as well as –technical considerations and –environmental issues and keeps them always in balance at all times. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 17  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Many delays and pitfalls can come from ill considered cost cuttings as with cost overruns Balance should be the key concept here. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 18  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS A design culture which applies good accounting tools is imperative for a successful project. We must remember that , "Good design shrinks Manufacturing costs” However departmentalized organizational structure in companies causes each department to try to minimize its own costs, passing problems on to the next department. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 19  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Designers often think that their extra work benefits other departments. The extra work required by the design people for “Design for Produceabilty and Testability” can be an example. Managers in industry, must emphasize the importance of "we're all in this together" spirit of cooperation. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 20  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Historically, design engineers have regarded all other responsibilities (test- manufacturing-marketing-servicing) as beneath them. They do the "important" work of creating the products, and someone else has to figure out how to make them reliably, how to market them succesfully, how to service them effectively. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 21  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS This attitude "throw the design over the wall and let manufacturing and test people deal with it" often begins at our educational institutions, where students learn how to design but only vaguely understand that “without cost-effective, reliable manufacturing operations, the cleverest, most innovative product design cannot succeed in the real world”. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 22  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Today, like the gradual acceptance of concurrent-engineering principles “Institutes in the western World are actively encouraging their students to recognize the practical-application aspects of their work”. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 23  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 24  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS In industry, the development process for a new product has four phases : –Feasibilty –Prototype –Pre-production –Production A design review should take place to proceed into the next phase. Duration of the design process is important for competition. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 25  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 1.The Feasibility Phase Decision about the product being technically and economically viable or not is given in this stage. The feasibility stage utilizes the inputs of –market survey and –estimated design and manufacturing costs A target price is determined and whether it is ACHIEVABLE OR NOT is examined. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 26  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Factors which would give an edge to our products in the market are : price technology and functionality better quality environmental acceptability 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 27  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS During this stage, companies should keep in mind the cost of not developing a new product at all too. Falling behind the technology may have drastic effects. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 28  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS In this phase, Marketing people should provide information on : functions expected from the product (Market Specifications) target price expected life time of the product Number to be sold maintenance and service concepts the technical specifications expected from the product annual / monthly / weekly sales rate 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 29  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS engineering design people should provide : specifications/functions to be met by the product duration time of the design process material cost of the product for the given specifications 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 30  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS manufacturing people should provide information on : test philosphy of the product investment necessary for the production and testing of the product manufacturing cost in terms of labour hours? 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 31  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS A feasibility study to find out the “break even point” of the product should be carried out at this stage also. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 32  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS At the end of this phase we must ensure that the product can be developed manufactured and sold at a cost and quality level that ensures business success 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 33  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS $ 300K 200K Investment+cost Break even point 100K Sales 6 12 18 Months 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 34  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS A final go/ no-go decision has to be given by the Top Management. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 35  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 2. The Prototype Phase In this phase, the first physical working model is realized in the laboratories. The aim is to determine whether the design specifications can be achieved within the cost constraints imposed by the market. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 36  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS During Prototype Phase: 1.The theoretical schematic circuit model has to be designed 2.The design has to be verified 3.A physical circuit has to be made and tested with laboratory capabilities 4.Engineering documentation has to be completed According to the results, the design has to be, –changed or –moved to the next step. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 37  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 2.1. Prototype Stage/ Schematic circuit design The process of schematic circuit design begins with the specifications. Specifications state the functionalities and abilities the finished design must provide. They dont indicate how it is to be achieved. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 38  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Schematic circuit design is the process where design specifications are realized into a theoretical electrical circuit model with – a number of electronic components and – their interconnections. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 39  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Design specifications specify the circuits functionality in terms of –inputs, outputs –physical parameters like size , weight eas of dismantling. –operational parameters like speed of operation,. Electromagnetic Interference (EMI) immunity power consumption. Electromagnetic Interference (EMI) emissions environmental compatibility moisture resistance, temperature range, vibration tolerance and acceleration tolerance 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 40  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS In schematic circuit design first a ‘’functional block diagram’’ is realised in which the contents of the blocks are not considered, Each block is viewed in terms of its input and output characteristics. This is sometimes referred to as a "black box" design. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 41  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS This approach allows complicated design tasks to be broken into smaller tasks. These tasks can be tackled –in sequence or –in parallel (divided) amongst members of a design team 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 42  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS In later stages, each block in the diagram is converted to detailed electrical circuit models to perform the required electrical functions. The individual circuit components are chosen to carry out each function in the overall design. One of the difficulties at this stage is the standardization of the components. Because of standardisiton, calculated component values in a circuit may not be purchaseable from suppliers. A good 'catalog engineering' will be necessary at this stage. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 44  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS There are two types of circuit design which require different aproaches: –Analog circuit design and –Digital circuit design. Analog circuit design is the –oldest of the design methods and –is the more complex of the two. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 45  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Analog designs can be functionally divided into well-established standard subcircuits. Component values in these subcircuits are modified to achieve the desired operational characteristics. Impedance matching between circuits must be carefully watched. Digital circuit design is comparatively easier. Because of the availability of low priced, well established integrated digital circuits, “the use of discrete components in digital design is very rare.” 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 46  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Computer Aided Design, CAD Computer aided design (CAD) or Electronic Design Automation (EDA) tools are popularly used in the design of circuits, particularly in analog circuits. Some popular design softwares are SPICE, PSpice, and Multisim. It is important to work with EDA softwares that interfaces directly with the available printed circuit board (PCB) development system. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 47  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS. CAD systems use component data bases which contain the –descriptions of components, –their circuit symbols, and –their electrical characteristics. A circuit model is designed by selecting components from the data base and then specifying a location for it in the circuit to be built up. CAD Sysytems perform simulations of circuits once they have been designed. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 48  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 2.2. Prototype Stage/ Design Verification This is the process of going through the circuit design (model) to ensure fullfillment of the specifications. This is usually a highly mathematical process and can involve large-scale computer simulations. Today most of the popular commercial CAD (or EDA) tools integrate circuit design and its simulation/verification process. After verification –It is very likely that problems will be found and –redesigning will be required to fix them. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 49  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Circuit simulation reduce development time by verifying designs and fixing errors before making the physical prototype. However, even with recent advances in simulation, there are still difficulties in modeling all types of devices (such as sensors and emulators). For example stray inductances and capacitances associated with the components is not easy to simulate. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 50  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS With increasingly complex designs and shorter development cycles, today's engineers must remove the guesswork from their electronic designs. For this engineers need to integrate verification with testing. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 51  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 2.3. Prototype Stage/ Physical realisation of the product and Testing In prototype stage a Physical model is achieved with laboratory capabilities, and tested. (Before this stage if necessary breadbording and breadboard testing can take place). Obviously these tests would be more on the functional side and would not give any indication of the shock and vibration characteristics of the design. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 52  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS During the implementation of the Physical model, we first have to make a Printed Circuit Board (PCB) with the correct lay out. Today manual layout method is replaced with computerised PCB development systems. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 53  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS The input to a PCB Development System is a circuit diagram and a parts list. An autorouter determines the path of the connections. The output is a series of files which include a –drill template, –track layout diagrams, (photographic positive or negative images). –solder resist patterns –and a legend pattern. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 54  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS These files (drawings) are needed to fabricate the printed circuit board (PCB). Files are simply sent to a circuit board fabricator. Design engineers should perform the schematic design/verification on a CAD system that is compatible with the PCB (Printed Circuit Board) development system that is in hand, so that the schematics file can be easily transferred. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 55  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Todays CAD systems allow the integration of the schematic circuit design, simulation/verification and PCB development processes. They provide the output files necessary for : –PCB production as well as –pick-and-place or insertion machines, and in-circuit testers in manaufacturing halls. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 56  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS The output files from the CAD and the PCB development sytems are an outcome of the prototype stage. PCB / IC (integrated circuit) development files are necessary for the production of printed circuit boards or Integrated circuits. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 57  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Layout files from CAD systems and mechanical data from mechanical design tools provide inputs to the shop floor machinery which all together make up a Computer Aided Manufacturing (CAM) system. Hence human errors due to manual data transfer is eliminated and cost and time is saved. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 58  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Integrated circuit design Once the circuit is designed and verified as in the conventional circuit design, it is necessary to convert the circuit descriptions into geometrical data for the manufacturing of the device. The geometrical data takes the form of a series of masks, one for each of the layers which make up the three dimensional structure of the integrated device. Masks are used in photolithographic processes during the device’s manufacture. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 59  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Computer aided design systems can create these geometrical layers easily by using the stored data in their libraries. They then convert these data into digital format for the use of the mask makers. Masks are very expensive, mistakes should be avoided. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 60  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Testing is the real-world counterpart to verification. “ Testing involves checking if the circuit really does what it was designed for”. The tests carried out in “prototype phase” on a laboratory scale are often called “alfa test”. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 61  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS The largest bottleneck in the design process is “design verification and testing”. Much of this is due to the performing intensive benchtop measurements manually in the lab. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 62  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Collaboration of –EDA tool manufacturers, –component vendors, and –test firms has integrated the worlds of test and design verification. Integration of measurements and simulated data improves the engineering productivity. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 63  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS It is then possible to seamlessly compare the real-world measurements against the simulated results. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 64  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS In this way designer can integrate tough-to-model components such as sensors into simulations by acquiring their real-world signals to drive circuit simulations. Similarly, designers can use simulation data to drive circuits under test. Furthermore, designers easily can compare –simulation data with real-world signals, shortening the prototype verification process and increasing confidence in the design. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 65  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS With rapid analysis, engineers can quickly view the results to reduce design periods. The ability to save measurements also makes it easy –to repeat measurements and –to convey the measurement tasks into manufacturing validation tests. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 66  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS* After testing , Components Test and manufacturing methods are finalised with strategic decisions on : – film technologies, – hybrid or monolithic Integrated circuits – custom made or off the shelf type of components – software strategy, (in-house or subcontracted software) – size constraints – built in testing capability – manufacturing and testing investment – price of the product 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 67  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 2.4 Prototype Stage/ Engineering documentation The result of the prototype stage is the instructions on “how to construct the physical electronic circuit and the product”. These are blueprints describing the , –size –shape –connectors, –artwork or CAM file for manufacturing the PCB’s or Integrated circuits –drawings for moulds and dies 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 68  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Any commercial design must include an element of documentation. The nature of this documentation will vary according to the size and complexity of the circuit. As a bare minimum the documentation will include at least the –specifications and –testing procedures of the design. A statement of compliance with current EU regulations (CE conformity) must also be included in the documentation for professional equipment. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 69  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Companies often underestimate the need for documentation because they underestimate the need to modify their products as time and technology advances. If not documented well, redesign is often the case which will be very costly to the company. Documenting and keeping them up to date are equally important tasks. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 70  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Modifications in the –components, –manufacturing methods and –testing methods should be carefully documented by taking the views of all related departments. Effectivity dates should be carefully chosen and followed in all related manufacturing departments. Such document and modification systems would improve the management of parts as well as maintenance and servicing of the products. Few owners and managers understand the importance of documentation 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 71  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS A well documented project pays back in a number of areas 1.Design and Manufacturing Method Changes will be possible even if the responsible personel leave the company 2.Customers will feel assured of the qulity of the products 3.Spare parts management , maintenance and servicing will be easier and unnecessary stocks shall be avoided 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 72  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS There are a number of types of documentation, 1.Design Documentation (Engineering dept.) 2.Test Documentation (Engineering department or production engineering dept.) 3.Manufacturing and assembly documentation (Production engineering dept.) 4.Procurement documentation (Engineerin Dept) 5.Installation documentation (Engineering Dept) 6.Maintenance documentation. (Engineering Dept) 7.Software documentation (Engineering Dept) 8.User/operator documentation (production engineering dept) 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 73  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 3. THE PREPRODUCTION STAGE In this stage a “prototype of the product” is prepared with production facilities and –a verification run is performed in the production environment to demonstrate the technology. Test carried out in this phase are often called β test.. Whether the product is ready for mass production or not is seen at this stage. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 74  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS The pre requisites for this stage are : 1.Engineering documents for testing 2.Component documentation for procurement 3.Documentation for PCBs, moulds and dies Documents for the assembly and testing of the product in the production environment are prepared by the production engineering departments at the end of this stage. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 75  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 4. THE PRODUCTION STAGE The purpose of the production stage is to prove that the product’s documentation is capable of supporting its production. Usually manufacturing a small number of products is tried first. This is called pilot production which fully employs the use of available production capabilities. It would be too risky to start manufacturing large numbers of an unproven design. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 76  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS This stage is the last chance to eliminate any faults in the product or in any of the manufacturing processes. If this first lot of production is succesfully accomplished then production with full capabilities can take place and large numbers can be produced (Mass Production). 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 77  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Problems can still occur during the mass manufacturing of new electronic products due to 1.Customer specification change 2.Availability of components 3.Changes in component specifications 4.Manufacturing process difficulties 5.Software problems and bugs These problems can be minimised or resolved easily if concurrent engineering is extended to production stages. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 78  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS –It is very normal to expect changes during design processes. –It is good practice to keep options open for as long as possible. –It's always easier to remove elements from the circuit than to put them in. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 79  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS EU and Environmental Considerations for Product Development : The amount of waste from electronic products and processes is becoming more and more important from environmental point of view. The waste from the –production processes and – at the end of the products life cycle should be carefully considered in the protype phase. It is interesting to point out that green products sell ! 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 80  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS The three measures that should be taken into account in the product and hence in the design process are : 1.Usage of environmentally friendly, recyclable components and materials 2.Ease of dismantling or repairing of the product. 3.Minimum energy consumption 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 81  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Another issue in the process of product design is the European Community’s Directives. According to the European Community’s approach, equipment must not harm the user and the environment ; Therefore certain equipment has to carry a “CE” plate (“European Conformite”) to indicate the safe usage of this equipment. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 82  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS However, not all products must bear the CE marking. The equipment that requires a CE Plate is given in the relevant “European Directives”. There are more than 20 directives setting out the product categories requiring CE marking. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 83  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS For Electrical Equipment generally two Directives are under concern : 1.The LV-Directive (73/23/EEC) : The LVD is not about electrical safety only. It also covers : – fire hazards, – mechanical hazards, – radiation – chemical hazards Future developments are expected to bring more into the scope of safety directives. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 84  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 2. The EMC (Electro Magnetic Compatibility) -directive (89/336/EEC) : This discipline investigates the unwanted emissions, and unwanted susceptibility of electronic equipment against Electro Magnetic Fields. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 85  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS If an equipment is carrying a “CE” Plate it indicates that the manufacturer has verified that the product complies with all relevant essential requirements of the applicable EU directive(s) and it can move around in the European Community countries. In other words CE sign is the “passport” of the equipment for the European Community countries. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 86  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Directives indicate whether an authorised third party (Notified Body) must be involved in the conformity assessment procedure for CE marking. These Bodies are authorised by national authorities and officially “notified” to the Commission and listed in the NANDO (New Approach Notified and Designated Organisations) database. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 87  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS The essential requirements in these directives are : 1.Safety 2.Health 3.Environment 4.Consumers protection The directives refer to the Harmonised European standards (EN - European Norms ) which express in detailed technical terms the essential requirements. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 88  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS The manufacturer has to take certain obligatory steps before affixing the CE marking : – set up a technical file for the assessment of the product’s conformity to the relevant requirements, – sign an EC declaration of conformity The documentation has to be made available to authorities on request. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 89  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS SYSTEMS ENGINEERING Due to the increased degree of complexity in design and development of systems most large engineering organizations now use some level of systems engineering. Systems engineering emerged during World War II. With todays large and complex systems the need for systems engineering has gained increased attention. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 90  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Systems are made up of component elements that are interconnected and programmed to function together. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 91  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS A system is defined as : a set of interrelated components that function together towards a common purpose. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 92  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Systems Engineering is an interdisciplinary approach to enable the realization of successful systems. It integrates all the disciplines and specialty groups into a team effort, forming a development process that proceeds from concept to operation. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 93  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Systems Engineering considers both the business and the technical needs of customers. The goal is to provide a quality product that meets the user needs 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 94  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Systems engineering is similar to concurrent engineering, but there are differences. Systems engineering concentrates primarily on function of the system whereas concurrent engineering considers both form as well as function of the system or product under discussion. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 95  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS A system design usually involves both analysis and synthesis. Design by analysis is accomplished by modifying the characteristics of an existing or standard system configuration. Design by synthesis is performed by defining the form of the system directly from its specifications. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 96  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Systems Engineering focuses on : –defining customer needs and required functionality early in the development cycle, –documenting requirements, then proceeding with –design analysis/synthesis and –system validation while considering the complete problem 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 97  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Implementing systems engineering (SE) requires the coordination of technical and managerial endeavors. VENN DIAGRAM 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 98  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS Processes used in systems engineering are :. Functional analysis (Customer needs, Investigation of alternatives, set system functional requirements,). Synthesis (Model the system, set Functional Performance Requirements of individual system elements, integrate). EvaIuation and decision (Launch the system, asses performance). Description (documentation that fully describes all elements of the system) 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 99  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 100  FUNDAMENTALS OF THE ELECTRONIC PRODUCT DEVELOPMENT PROCESS At the end of system engineering – performance, – design, – test requirements – environmental requirements – interface design requirements must be specified and documented for the systems equipment, components, and software. It is important to remember that the goal of the systems engineering process is not to define the actual design. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 101 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 102  QUIZ Use the two words TESTING and DESIGN VERIFICATION appropriatly in the following sentence Integration of measurements in ……………………… and simulated data in ……………………. improves the engineering productivity. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 103  Kısa Sınav - 1 Sanayideki ‘’ürün geliştirme sürecinde’’ izlenmesi gereken yol olarak önerilen ‘’eşzamanlı mühendislik’’ kavramından ne anlıyorsunuz ? Bir cümle ile açıklayınız. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 104  QUIZ 2 CE plate on a product indicates whether it is in accordance with the............................. and shows that it can travel between European community countries. A)EU norms B)EU directives C)EU standarts 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 105  quiz Ürün yaşam döngüsünü tasarımın erken aşamalarında gözönünde bulunduran sistematik ürün geliştirme yaklaşımına ……………………… adı verilir. 10/24/24 ELE 423 Dr. Zeki U. KOCABIYIKOĞLU 106