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

2. 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

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

4. 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

5. Projects and Demos
MIT HTMAA Final Projects

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

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

8. Product Architecture: System Block Diagram
What are we building?

9. Product Architecture: Industrial Design Sketch
What are we building?

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

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

12. 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?

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

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

15. 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.

16. 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

17. The Supply Chain

18. 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.

19. 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.

20. Small Component Vendors

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

22. Printed Circuit Fab

23. Wafer Fab

24. Machine Shop

25. Injection Molding Factory

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

27. Contract Manufacturers

28. Contract Manufacturers

29. Contract Manufacturers

30. Contract Manufacturers

31. Contract Manufacturers

32. 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.

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

34. Resources Proto Labs Protomold Quick-turn Injection Molding
AQS (All Quality and Service) Freemont, CA and Shenzhen, China PCB Assembly and Turnkey Contract Manufacturing
Proto Labs Protomold
Quick-turn Injection Molding
Protocase
Sheet metal electronics enclosures
ProtoLabs First Cut
Quick-turn CNC Machining with geometry limitations
AllJack Premium Factory
CNC Machining and Product Appearance Models
Digi-Key
Electronic Components
DSH Mould
CNC Machining
Advanced Circuits
Quick-turn Printed Circuit Boards
Mouser
Electronic Components
Jack’s Machine Company
Hanson, MA
Waterjet Cutting
TTM Technologies
High Technology Printed Circuit Boards
McMaster-Carr
Mechanical Components
XACT Wire EDM Corporation
Electric Discharge Machining
Streamline Circuits
Printed Circuit Boards
Admiral Metals / Metal Source
Woburn, MA
Non-ferrous metals, Local pickup
BJA Magnetics
Custom magnets and magnetic assemblies
AP Circuits
Quick-turn Printed Circuit Boards
Scientific Alloys
Westerly, RI
Custom rolling and forging
Atlantic Industrial Models
Essex, MA
CNC machining, Sheet metal
Advanced Assembly
PCB Assembly