Transition to Manufacturing MIT MAS 863 How to

Transition to Manufacturing MIT MAS. 863: How to Make Almost Anything December 7, 2017 Ara N. Knaian Principal Engineer NK Labs, LLC

Example: Apple i. Phone What this talk is about x 109 First Prototype i. Phone/i. Pad Production i. Phone Capacitive Multitouch Background Science, Technology and Product Concepts Curated App Store New Technology “Secret Sauce” 2. 3 billion smartphones users in 2017

Product Development Roadmap (in theory) Product Requirements Document Architecture Projects Demos, Testing Technology Know-How and IP EVT DVT PVT Ramp MP

Product Development Roadmap (closer to real) New Version PRD infeasible Product Requirements Document New Product Idea Architecture Projects Skunk Works Demos, Testing Technology Know-How and IP EVT DVT PVT Respin Focused Technology Development Revisit Architecture Corporate R&D Ramp MP

Projects and Demos MIT HTMAA Final Projects

Product Requirements Document “A product is not a collection of features. ” A product solves a actual problem faced by actual people. .

Product Requirements Document What is it for? Why build it?

Product Architecture: System Block Diagram What are we building?

Product Architecture: Industrial Design Sketch What are we building?

Engineering Validation Test Can we build one unit, by any means necessary, that meets the product functional requirements?

DVT (Design Validation Test) Can we build a bunch of units that meet the product functional requirements, look great, and have stable software?

PVT (Production Validation Test) Can we build a ton of units in the real factory with a high yield, at a production cost compatible with the sales price?

Ramp Can our factory and our supply chain handle the production volumes we need?

MP (Mass Production) Does the world need our product? Can we expand into new markets? What should we build next?

Design for Manufacturing • Tolerances, Tolerance Stack-Up • Electrical and Mechanical • Stay within every datasheet specs all the time every time • Do design reviews with the factory, and listen to their advice • Design for High Yield • Design for CE, UL, FCC, etc.

The Product of Engineering is Documentation • Bill of Material • Gerber Files • Solid Models • Mechanical Drawings • Process Instructions • Test Instructions • Software Binaries • Designs for production jigs and fixtures

The Supply Chain

Supply Chain • Materials Suppliers • Component Suppliers • Job Shops • Contract Manufacturers An OEM can live or die by its supply chain. A good supply chain is just as important as a good engineering design.

Component Vendors A component vendor has a catalog of standard components. If you are big enough, they will also produce similar custom components for you.

Small Component Vendors

Job Shops A job shop specializes in a particular set of manufacturing process. They produce custom components to your specifications.

Printed Circuit Fab

Wafer Fab

Machine Shop

Injection Molding Factory

Contract Manufacturers do the final assembly and test of your product. They buy components from component suppliers and job shops.

Contract Manufacturers

Contract Manufacturers

Contract Manufacturers

Contract Manufacturers

Contract Manufacturers

Summary • First you need a product worth manufacturing. • The last 1% takes 99% of the effort. The difference between a prototype and a product is massive. • The product of engineering is documentation. • An OEM lives and dies by its supply chain. • Job shops are an amazing enabler of small OEM’s.

On a personal note… Seeing a real consumer using your product “in the wild” is exciting, even years later.

Resources AQS (All Quality and Service) Freemont, CA and Shenzhen, China PCB Assembly and Turnkey Contract Manufacturing http: //www. aqs-inc. com Proto Labs Protomold Quick-turn Injection Molding http: //www. protolabs. com Protocase Sheet metal electronics enclosures http: //www. protocase. com Proto. Labs First Cut Quick-turn CNC Machining with geometry limitations http: //www. protolabs. com All. Jack Premium Factory CNC Machining and Product Appearance Models http: //alljack. com Digi-Key Electronic Components http: //www. digikey. com DSH Mould CNC Machining http: //www. dshmould. com Advanced Circuits Quick-turn Printed Circuit Boards http: //www. 4 pcb. com Jack’s Machine Company Hanson, MA Waterjet Cutting http: //www. jacksmachine. com TTM Technologies High Technology Printed Circuit Boards http: //www. ttmtech. com Mc. Master-Carr Mechanical Components http: //www. mcmaster. com XACT Wire EDM Corporation Electric Discharge Machining http: //www. xactedm. com Streamline Circuits Printed Circuit Boards http: //streamlinecircuits. com Admiral Metals / Metal Source Woburn, MA Non-ferrous metals, Local pickup www. admiralmetals. com BJA Magnetics Custom magnets and magnetic assemblies http: //www. bjamagnetics. com Atlantic Industrial Models Essex, MA CNC machining, Sheet metal http: //atlanticind. com AP Circuits Quick-turn Printed Circuit Boards http: //www. apcircuits. com Advanced Assembly PCB Assembly http: //www. aapcb. com Mouser Electronic Components http: //www. mouser. com Scientific Alloys Westerly, RI Custom rolling and forging www. scientificalloys. com