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

Background Science, Technology and Product Concepts Example: Apple iPhone What this talk is about x 109 First Prototype iPhone/iPad Production iPhone Capacitive Multitouch Curated App Store New Technology “Secret Sauce” Background Science, Technology and Product Concepts 2.3 billion smartphones users in 2017

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

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

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 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 Proto Labs Protomold Quick-turn Injection Molding 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 ProtoLabs First Cut Quick-turn CNC Machining with geometry limitations http://www.protolabs.com AllJack 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.4pcb.com Mouser Electronic Components http://www.mouser.com Jack’s Machine Company Hanson, MA Waterjet Cutting http://www.jacksmachine.com TTM Technologies High Technology Printed Circuit Boards http://www.ttmtech.com McMaster-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 AP Circuits Quick-turn Printed Circuit Boards http://www.apcircuits.com Scientific Alloys Westerly, RI Custom rolling and forging www.scientificalloys.com Atlantic Industrial Models Essex, MA CNC machining, Sheet metal http://atlanticind.com Advanced Assembly PCB Assembly http://www.aapcb.com