The Phases of Hardware Product Development: From Concept to Shelf 

Introduction

Product development in hardware design is a multifaceted process that extends beyond the purview of just the electrical engineering (EE) or RF teams. It is an intricate collaboration involving a diverse set of teams ranging from validation, mechanical product design, factory quality, reliability, to compliance. Each of these teams brings a unique perspective and set of skills to the table, ensuring a comprehensive approach to product development.

Background

The product design team, predominantly composed of mechanical engineers, is entrusted with tasks such as designing enclosures, selecting connector types, and determining allowable board space and height. Their designs are typically guided by the specifications and vision provided by the industrial design team. On the other hand, the electrical engineering division comprises specialized units such as digital system EE, RF system EE, and other niche teams focused on areas like antenna design, power management, and validation. These teams work in tandem to bring the product's electronic aspects to life.

In essence, product development is not a solitary endeavor but a synergistic one.

Overview
Schedule:
The overarching program timeline is influenced by the product roadmap, with a single product's development generally spanning 1 to 2 years. Throughout this period, each development stage typically follows a build schedule ranging from 6 weeks to 3 months.

Block Description

1. Development (Proof of Concept)

• Focuses on selecting suitable chipsets and verifying crucial hardware components.

• Uses larger PCB boards to test basic chip interconnects and functionalities.

• Aims to pave the way for software development and to finalize hardware architecture selections.

2. Proto (Prototype Design)

• Aligns with the exact mechanical component outline (MCO) provided by the product design team.

• Validates the placement and routing of all hardware components within the specified board space.

• Involves fitting the PCB, Antenna, and other electrical modules within a casing designed by the product team.

• Kick-starts the validation testing phase.

3. EVT (Engineering Validation Testing)

• Marks the "EE hardware lock stage."

• Finalizes test results and implements necessary changes in the schematic and layout.

• Restricts any electrical engineering design changes post this stage, although slight adjustments may still be made by the product design team.

• Begins regulatory compliance testing.

4. DVT (Device Validation Testing)

• Known as the "Mechanical Hardware Lock stage."

• Seals all mechanical designs in preparation for mass production.

• Completes regulation certification for the hardware.

5. PVT (Production Validation Testing)

• Termed the "Factory assembly line Lock stage."

• Assesses factory readiness for mass production, identifying bottlenecks and determining the assembly lines required for the launch.

• Transitions product development from the design teams to the operations team.

6. MP (Mass Production)

• Represents the final stage where the factory operates at full capacity.

• Ramping up can vary from a few weeks to months based on sales projections.

7. Shipment

• Products are packaged and dispatched either by sea or air to designated regions.

8. On Shelf

• After shipment, products are transported to retail locations, allowing time for import paperwork in the target sales regions.

9. Product Announcement

• The company officially unveils the product and commences sales.

In Practice

• A two-week gap exists between design release and hardware building commencement.

• Another week is reserved for hardware assembly and an additional week for shipping to the design team.

• Thus, hardware validation typically begins after a month's wait.

• In a 6-week building schedule, only 2-3 weeks are available for testing and design modifications.

• Due to various challenges, multiple proto and EVT builds might be necessary to perfect the design.

Summary and Conclusion

• Product cycles generally span one to two years.

• Build schedules can vary from 6 weeks to several months.

• Time constraints often compress the validation and design schedule.

• Additional builds are frequent in the industry to rectify minor but vital issues.

• Hardware design typically demands precision in early stages to avoid complications later. Once a product leaves the factory, modifications become impossible. Hence, thorough validation and design adjustments at the outset are essential.

From our examination, it's evident that hardware design usually has limited opportunities for iterations, and the timelines are invariably stringent. Once a product departs the factory, turning back is not an option. Thus, as diligent engineers, it's imperative to address all design modifications and conduct thorough validation testing early on, ensuring a smooth progression and mitigating potential complications in subsequent stages.