Table Of ContentCopyright 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
Description:Product development is the magic that turns circuitry, software, and materials into a product, but moving efficiently from concept to manufactured product is a complex process with many potential pitfalls. This practical guide pulls back the curtain to reveal what happens—or should happen—when you take a product from prototype to production. For makers looking to go pro or product development team members keen to understand the process, author Alan Cohen tracks the development of an intelligent electronic device to explain the strategies and tactics necessary to transform an abstract idea into a successful product that people want to use. Learn 11 deadly sins that kill product development projects Get an overview of how electronic products are manufactured Determine whether your idea has a good chance of being profitable Narrow down the product’s functionality and associated costs Generate requirements that describe the final product’s details Select your processor, operating system, and power sources Learn how to comply with safety regulations and standards Dive into development—from rapid prototyping to manufacturing Alan Cohen, a veteran systems and software engineering manager and lifelong technophile, specializes in leading the development of medical devices and other high-reliability products. His passion is to work with engineers and other stakeholders to forge innovative technologies into successful products.
