technical machine's hardware playbook
DESCRIPTION
Technical Machine's approach to manufacturing. Learn more at http://tessel.io Video of the talk: https://www.youtube.com/watch?v=0ZArxLeflegTRANSCRIPT
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Technical Machine’s
Hardware Playbook
@jia | Jia Huang | co-founder & developer
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Tessel is a WiFi-enabled microcontroller that runs JavaScript.
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15 electrical designs, $250k preorders
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2 manufacturers2 manufacturing locations
MA, USA● makes Tessel● we manage most of the
supply chain
ShenZhen, China● 14 modules● higher overall volume
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Tessel Timeline
June July September December2013 2014
Work on Tessel starts
Work on 14 modules start
Tessel is “minimally functional”. Launched Crowdfunding campaign.
Majority of products are pushed into production. A few are held back pending firmware changes.
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Tessel Timeline
June July September December2013 2014
Work on Tessel starts
Work on 14 modules start
Tessel is “minimally functional”. Launched Crowdfunding campaign.
Majority of products are pushed into production. A few are held back pending firmware changes.}
6 months
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Tessel Timeline
June July September December2013 2014
Work on Tessel starts
Work on 14 modules start
Tessel is “minimally functional”. Launched Crowdfunding campaign.
Majority of products are pushed into production. A few are held back pending firmware changes.}
6 months15 designs
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Tessel Timeline
June July September December2013 2014
Work on Tessel starts
Work on 14 modules start
Tessel is “minimally functional”. Launched Crowdfunding campaign.
Majority of products are pushed into production. A few are held back pending firmware changes.}
6 months15 designs
1.5 Hardware Engineers( )
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Tessel Timeline
June July September December2013 2014
Work on Tessel starts
Work on 14 modules start
Tessel is “minimally functional”. Launched Crowdfunding campaign.
Majority of products are pushed into production. A few are held back pending firmware changes.}
2.5 designs/month
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This is how we do it.
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Production TimelineProduction Timeline
Engineering
Design TestPrototype Test Rig Test Plan
Supply Chain
Sourcing Check volumes Place order Re-source
Look into manufacturers Selection Pre-production ProductionDFM
Manufacturing
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Engineering
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Design / Prototype / Test
First pass (~10 days)
1-3 days design 3 days PCB turn1 day build 2-3 days test
design review
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Design / Prototype / Test
First pass (~10 days)
1-3 days design 3 days PCB turn1 day build 2-3 days test
design review
7 days write test code
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Design / Prototype / Test
First pass (~10 days)
1-3 days design 3 days PCB turn1 day build 2-3 days test
design review
7 days write test code
Subsequent passes (~5 days)
1 day redesign 3 days PCB turn 1 day build/testdesign review
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Prototype Manufacturers
AP Circuits
Alberta, Canada3 day turns$10/sq inch
KL, Malaysia1.5 week turns~$70+
ShenZhen, China2.5 week turns$10/ 40 sq inches
KL, MalaysiaPCBA 3 week turns ~$300+ setup, $8/sq inch
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Test RigsTessel tests Tessel Tessel tests modules
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Test Plans
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Test Plans
● Revision #s and dates
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Test Plans
● Revision #s and dates● contact info
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Test Plans
● Revision #s and dates● contact info● Don’t assume English
proficiency
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Test Plans
● Revision #s and dates● contact info● Don’t assume English
proficiency● Have redundancy
among test rigs
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Test Plans
● Revision #s and dates● contact info● Don’t assume English
proficiency● Have redundancy
among test rigs● images
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Test Plans
● Revision #s and dates● contact info● Don’t assume English
proficiency● Have redundancy
among test rigs● images● setup info
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Test Plans
● Revision #s and dates● contact info● Don’t assume English
proficiency● Have redundancy
among test rigs● images● setup info● clear indicator of
pass/fail
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Supply Chain
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Sourcing
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Sourcing
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Sourcing
Online prices are fake. Find an inside sales guy.
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Part Swaps
Manufacturer should recommend swaps.
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Part Swaps
● Things that are stupidly expensive but shouldn’t be○ connectors○ crystal oscillators○ buttons○ anything that is a passive component
Manufacturer should recommend swaps.
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Double checking
Make sure there is enough supply
10k supply, 26 week lead time and someone else buys them out 1 month before production starts?
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Double checking
Make sure there is enough supply
10k supply, 26 week lead time and someone else buys them out 1 month before production starts?
1. Cry
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Double checking
Make sure there is enough supply
10k supply, 26 week lead time and someone else buys them out 1 month before production starts?
1. Cry2. Find a drop in replacement
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Double checking
Make sure there is enough supply
10k supply, 26 week lead time and someone else buys them out 1 month before production starts?
1. Cry2. Find a drop in replacement3. There are none?
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Double checking
Make sure there is enough supply
10k supply, 26 week lead time and someone else buys them out 1 month before production starts?
1. Cry2. Find a drop in replacement3. There are none?4. Do a redesign through the tears.
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Double checking
Make sure there is enough supply
10k supply, 26 week lead time and someone else buys them out 1 month before production starts?
1. Cry2. Find a drop in replacement3. There are none?4. Do a redesign through the tears.
Check errata documents
● Manufacturer only tests 1 axis of an accelerometer during production?
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Double checking
Make sure there is enough supply
10k supply, 26 week lead time and someone else buys them out 1 month before production starts?
1. Cry2. Find a drop in replacement3. There are none?4. Do a redesign through the tears.
Check errata documents
● Manufacturer only tests 1 axis of an accelerometer during production?
● Parameters said 2 USB ports on MCU but only 1 is functional.
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Manufacturing
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Getting a manufacturer
1. What kind of volumes? ○ <1k○ <10k
(Both China and America support these volumes)
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Getting a manufacturer
1. What kind of volumes? ○ <1k○ <10k
2. Send in Gerbers & Bom for quotation. ○ Get a price breakdown
(Both China and America support these volumes)
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Getting a manufacturer
1. What kind of volumes? ○ <1k○ <10k
2. Send in Gerbers & Bom for quotation. ○ Get a price breakdown
3. Questions to ask○ What’s their typical client volume?
(Both China and America support these volumes)
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Getting a manufacturer
1. What kind of volumes? ○ <1k○ <10k
2. Send in Gerbers & Bom for quotation. ○ Get a price breakdown
3. Questions to ask○ What’s their typical client volume?○ Do you need special testing? FCC?
(Both China and America support these volumes)
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Getting a manufacturer
1. What kind of volumes? ○ <1k○ <10k
2. Send in Gerbers & Bom for quotation. ○ Get a price breakdown
3. Questions to ask○ What’s their typical client volume?○ Do you need special testing? FCC?○ Do they use 3rd parties?
(Both China and America support these volumes)
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Getting a manufacturer
1. What kind of volumes? ○ <1k○ <10k
2. Send in Gerbers & Bom for quotation. ○ Get a price breakdown
3. Questions to ask○ What’s their typical client volume?○ Do you need special testing? FCC?○ Do they use 3rd parties?○ If something goes wrong, who are you going to be
interfacing with?
(Both China and America support these volumes)
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China vs AmericaCosts (sample size ~10 manufacturers)
China Chinese with American office
American American with Chinese office
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China vs AmericaCosts (sample size ~10 manufacturers)
China Chinese with American office
American American with Chinese office
China● Really good at part
swaps / DFM
America● Really good at English
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Pre-production
● Quality● Communication● Test Process
Do a pre-production run. (10+ units)
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Production
Put out fires.
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Production
Put out fires.Pray.
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YMMV. https://[email protected]@technicalhumans