Project Schedule for Electronic Appliances
Concept/feasibility
- Form, Fit, and Function
- Can it operate at maximum tolerances
- Does it violate any patents
- Are there any similar products to use in design
- What Agency approvals will be needed
- Estimate volume and price targets
- Are custom parts needed and obtainable
- Displays, Membrane switches, Transformers, Sensors,
Housings, etc.
- Finalize functional specifications
Capture Schematic
- Consult AVL (Approved Vender List)
- Create any new parts, symbols and footprints
- Make BOM
- Get pricing based on volume
Lay out PCB
- Get current capacity for ground and output traces
- Establish mechanical keep-aways
- Estimate overall size
- Make sure inputs are sufficiently isolated from noise sources
- Make development boards with no solder mask
- Submit to ICT and function test Engineers (preliminary)
Make CAD drawings of mechanical parts
- Locate displays and input buttons (see Marketing)
- Locate mechanical stress points and strengthen them
- Mounting scheme and brackets
- Specify assembly procedure.
- any special tools or precautions
Contact Agency approval offices
- Get pricing and open new project
- Get critical test requirements
- Will it be necessary to visit facility for testing (UL, FCC)
- If so, which facility, how much does it cost,
what’s their lead time
Order Parts
- Enough for 5 -10 boards for development
- Get pricing and lead time for expected volume for rare components
- Make sure no parts are expected to become obsolete soon
- Identify alternative parts for critical components,
- output transistors, relays, buzzers, buttons, connectors,
displays, transformers, op-amps
- PCB should accommodate all alternate parts
- Submit drawings to vendors for quote of custom items
- Displays, Membrane switches, Transformers, Housings,
Plastic retainers, etc
Start ICT and Function test Engineers designing for boards
- Theory of Operation for how it functions
- Sequence of button pushes, inputs needed, outputs expected,
how it will be programmed
- Test points, pass/fail requirements, test code
Notify Manufacturing of product
- BOM
- Assembly procedure
- Special handling of vulnerable components
- Testing procedure
- Packaging requirements
Notify purchasing to prepare for Pilot Run
- BOM, Prints for custom parts, expected date of Pilot Run
Start Documentation
- Verification test procedure
- How to tell it is functioning, exercise all components
- Validation test plan
- Component temperatures, Hi line, low line,
Hi temp, low temp, FCC compliance,
relay and transformer qualification tests,
Then destructive test such as FMEA table, Surge testing,
Vibration and drop tests
- Software Check out plan
- Are there any unexpected states or state changes
- Theory of Operations
- Used by Diag + Repair, Test Engineering
- Worse Case Analysis
- Make sure no components ever operate outside
the tolerances listed in their datasheets
(calculations in theory)
- Diagnostics and Repair Manual
- User Guide
Develop prototype units
- Populate prototype boards (no solder mask)
- Use to develop hardware and software
- Identify and fix any software bugs
- Does software handle sensors, buttons, displays, and outputs
- Confirm that it operates under maximum load
- Identify hot components, get bigger resistors or transistors
- Identify noisy circuits that may need shielding
- Does transformer need TCO
- Do preliminary validation tests for worst case load,
component temperatures, hi-line, low-line,
FCC, hi-temp, low-temp, injected noise, surge testing
- Check for physical fit in end product
- Assemble final product, Identify any difficulties
- Make sure custom parts operate correctly and fit as designed
Preparation for Pilot run
- When satisfied with development, finalize schematic, BOM, PCB layout,
prints for custom parts and any assembly drawings for production.
- Notify Test Engineers of final layout so they can finish ICT and Function
testers
- Notify Manufacturing of final assembly drawings to prepare for Pilot run
- Notify Purchasing of final changes to BOM and drawings
Pilot run of production
- Construct assembly line and stock parts
- Post instructions and train personnel
- Take notes on any difficulties and change prints if necessary
- Confirm QC testing meets expectations
Finish Validation testing
- Use Pilot units to complete in depth Validation test plan
- Confirm preliminary Validation, UL, FCC testing results
- Do destructive tests, drop, vibration, temp cycling, FMEA
- Do any field testing
Release to Production
- Finish Documentation
- Validation test plan
- Agency approvals (FCC, FCC, etc.)
- Mechanical Prints
- Hardware Specification
- Theory of Operation
- Worse Case Analysis
- Diagnostic + Repair manual
- User Guide
- Incoming Inspection Instructions
- Notify Packaging Engineer
- Identify any special electronic or mechanical concerns
- Initiate final ECR to release
Be available for any quality issues that may occur in manufacturing or
returns from the field.
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