Product Design (Hardware) Part 3

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Hi, I'm Matthew Clark. This is less than 5.3 product designed hardware. Part three

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in this lesson will do a quick review of the product design process.

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We'll discuss prototyping and testing and moved to pilot and then building ship.

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Finally, we will conclude by talking about continuous improvement. So let's get started. So here we are in the product development process. In our previous lesson, we discussed Phase one concept, feasibility and design,

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and now we're gonna talk about Phase two and Phase three.

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Phase two consist of the design phase, which we've already covered. That stage overlaps both phases one and two and represents the fact that sometimes the work is intuitive

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and face to also has the prototype with the validation and adjustment and pilot stages with both manufacturing and assembly line validation.

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So let's talk about the manufacturing prototypes, the design verification of the DVT. So basically, this is the test it stage. It's part of the time to product.

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This is where you will finalize your cosmetics, perform final testing and set up your first assembly line.

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The engineering and development teams will put together the Assembly's.

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This is the stage that starts handing things off to the actual factory that will produce the product.

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It's also the most intensive stage of testing.

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Theo AM will perform system integration, testing and environmental reliability testing.

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The O. E. M will finalize the look and feel the product and put the final touches in place and test whether the product as a whole will withstand environmental stresses. They also check to see if the product complies with the rules and regulations and has the proper certifications as needed. Such as from the SEC are the proper UL ratings

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as to find in the production

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requirement document.

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The engineering team will also inspect every part they'll conduct testing on the prototypes. Drop testing, stress testing, shock testing, environmental testing. If the products must be waterproof, they'll test that

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they'll look at for exterior checks. Chips cracks in the Finnish color fades. Class breaks. They'll also test the battery.

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It's also important that the PCB is tested during this stage because production issues can occur midway through a production run and a wrong half cent resistor. Being loaded onto a board can ruin the entire board, and it's critical to figure out how much you can about the production design at this stage because this time goes on,

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changes become more expensive and time consuming as the product matures.

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So let's take a look at the design for Simply and design for manufacturing.

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Designed for assembly or DFA, is the process where products are designed for assembly of parts in mind. They're concerned more with reducing product assembly cost and focusing on the product assembly process. The OM will organize the production lines to minimize assembly operations.

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Theo AM also focused on the number of parts handling of those parts during assembly and the ease of overall assembly, which can drive time up and cost. Ah, fun fact. Henry Ford reduced the time it took to build a car from 12 hours to 2.5 hours. By using a moving assembly line,

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you could say that was the first design for assembly that occurred

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D fmr designed for manufacturing. This references the process of designing the product for ease of manufacturing from the assembled parts.

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The goal is to reduce the complexity of manufacturing and increase the optimization of the manufacturing process. Items covered in this step include the stencil for the PCB that will be completed, ensuring the bowls are already in. The OM will conduct final bolding test.

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These two steps are often combined together and what's called design for Manufacturing and Assembly or D F m. A.

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The underlying goal here is to produce a product cheaper and faster while reducing waste both effort and physical scrap.

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This is done by identifying as early in the process is possible, the optimal part design, material flow and assembly and fabrication operations.

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It's estimated that designed accounts for 70 to 80% of influence of a price quality and cycle time, whereas manufacturing only accounts for 20 to 30% of the influence.

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So for a small company in their first product, the pilot production, they might run in batches of 50 units for a large company or next. Gen product. Your pilot production will probably be batches of 100 units.

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So what does security look like? A. This stage well, the Simpsons team will need to be embedded working with the engineering on ensuring applicant framework controls for being addressed. It's a critical that in the manufacturing process that steps were not taken to reduce security. Think handling of identity, for example, the creation of the key material and certificates

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and storing and retrieving that material in the manufacturing process

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and securely injecting identity and of the devices, and also consider protection of the device firmware as well. The Sips A team will also need to stay focused on conducting security code reviews of firmware applications, Web designs AP ICE and establishing processes for ongoing security after the product launch,

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such as user access reviews, or

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looking at the CBS root account access and so forth,

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as well as planning for data protection such as privacy planning or credit card handling. Our credit checks if that's part of the process

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and product security is about the product but their hooks into other areas of the business, which may be handled by other security and risk organizations, so coordination activities will need to be conducted as well. So let's talk about the pilot stage manufacturing pilots, product verification. The PVT. This is basically the produce it stage.

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It's part of the time to product.

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It's the most expensive stage of testing.

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This is where you validate the assembly line is properly optimized. You validate production line for parts delivery and set up you validate the test benches are properly and accurately testing the product for quality assurance for small company and first product. You're probably looking at micro production of batches of 50 to 100 units,

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large company next year, and you're probably looking at batches of 2000 units.

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So what's the security at this stage? What you're probably looking at fuzzing activities, penetration, testing of the device and the application and the I O T ecosystem, as well as a privacy sign off.

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So moving on to phase three of the product development process. This is where we introduce the building ship or the mass production and the continuous improvement or that make it better.

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So building ship this is the ship it stage or the saying goodbye stage. This is where you scale to production needs. You consider failure analysis and you really perfect the product packing, making final adjustments. Given the feedback of the first sales

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security at this stage you're conducting factory audits are too much product being produced as a factory producing knock off products besides actual products, warranty analysis and may show fraudulent products being sold. That's where you're gonna conduct fixed verifications or incident response planning,

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which takes us to the continuous improvement or make it better stage. This is where we conduct product improvements. We issue updates and patches, and we really flesh out the end of life planning the security. The stage is where we're conducting Delta's on our initial security assessments,

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and we're really doing security for C I. D. The continuous integration and delivery.

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And let's talk about bugs for a minute. This includes hardware and firmware and application bugs. If a bug is called early in the requirements gathering phase, the cost will likely be around $100.

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If the bug is detected in the Q A phase, the cost is likely to be around $1500 or a couple hours of development time.

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If it's not found until production, the cost could be is highest $10,000.

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But if it's detected after the product has been sent to the field, that cost could be many, many times more.

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Let's talk about the cost of software bugs that are sent out to the field. The first one will be Marina one.

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The U. S. First attempted to send a spacecraft of Venus in 1962 the $18 million rocket carrying an unmanned spacecraft veered off course just as it made its way past Cape Canaveral.

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A NASA range safety officer had to issue a self destruct command 290 seconds after liftoff. Well, what went wrong? While official reports indicate that computer code and the guidance system was missing a hyphen,

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which caused incorrect guidance signals being sent to the rocket

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the next one, let's consider Toyota's recall.

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Toyota had a recall for an accelerator sticking in 2009. Alexis S 3 50 accelerated out of control two speeds over 100 miles an hour.

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As a result, nine million cars were re called for a software bug in the antilock brake system.

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It's estimated that legal liabilities, incentive campaigns and marketing efforts cost the company over $3 billion.