Economics of Development and Production of Electronic Devices Volume 3
In the first and second parts, we covered the functional characteristics of the device, technical and economic analysis, as well as the development of the electrical schematic and PCB layout. In the final part, we will focus on prototyping, testing, certification and, last but not least, the start of mass production and product launch.
The three-part series on the economics of electronic device development and manufacturing is coming to an end.
Prototype Production
We have designed the PCB, and so we are now in the process of developing the device to the prototype production phase. In this step we need to specify the production of the PCB and then fit it with components. If the product has custom mechanical parts, then we also need to manufacture them so that we can test the product including the mechanical parts.
We assume that most development companies are not equipped with the technology to manufacture PCBs, and will therefore need to outsource their manufacture to a specialist partner company. PCB production can be outsourced to companies both in the Czech Republic and abroad, especially in Southeast Asia.
Outsourcing PCB Prototype Production: in the Czech Republic or Abroad?
Both approaches have their pros and cons. If you don’t have much experience in outsourcing PCB production and prefer simple communication and speed of delivery, then choose one of the domestic companies. The advantage is also the possibility of a personal visit, inspection of the technology and individual arrangement.
If you already have some experience and are not afraid of sometimes a little complicated communication, then feel free to outsource the production to one of the proven Asian companies. They can often impress with both price and speed of delivery.
When producing a PCB prototype, we are generally interested in quality and speed of delivery. Therefore, we always recommend outsourcing prototype production to proven companies that consistently ensure high quality production. This avoids defects caused by poor quality PCB manufacturing. The price aspect does not play a primary role in the case of prototype production. On the other hand, with each additional hardware revision, the total cost of prototype production increases.
Mounting of the Prototype PCB
You can also have a partner company assemble the prototype PCB. However, if you have the right equipment and enough experience, you can also perform the assembly yourself. The right approach depends on the complexity of the board and the number and type of electronic components involved. These factors should also be considered when planning prototype production.
If you produce only a small number of prototype PCBs per year and have basic equipment such as a manual soldering station, it is certainly worth considering outsourcing the assembly or using automatic or semi-automatic assembly at a specialist company. If we calculate the costs honestly, manual assembly can be comparable in cost to machine assembly, with the difference that machine assembly is much more reliable and provides consistently higher quality. This can have a significant impact on the overall efficiency of prototype production.
The exception is simple PCBs with low component density, which can also be assembled reliably and efficiently by hand. If you produce dozens of prototype PCBs per year, it may be advantageous, especially in terms of time flexibility and production deadlines, to purchase equipment for semi-automatic PCB assembly and train personnel to assemble the prototypes in-house. This approach can provide greater control over the entire prototype production process.
Equipment for semi-automatic assembly typically includes at least a digital solder paste dispenser, a semi-automatic assembly system and a reflow soldering oven. Deciding on the assembly method therefore always depends primarily on your current capabilities, equipment and expertise. It should be remembered that poor-quality assembly can cause a number of problems later during testing, potentially leading to the destruction of the prototype. In such cases, the direct financial loss is compounded by delays in development deadlines, making reliable assembly an important part of successful prototype production.
Testing and Certification in PCB Prototype Production
The final phase of electronic device development is testing and certification. Effective testing is an essential part of PCB prototype production and requires a clear plan and methodology for each test to be established in advance. Testing without adequate preparation increases the risk that defects or non-conformities with the specification will not be detected in time or may not be detected at all.
Internal Prototype Testing
During internal testing, especially of the first prototype, discrepancies with the specification and functional characteristics may be identified, potentially leading to the need to redesign the device. This means that we have to go through all the previous phases again. This is also where we can see whether we have been precise in the previous phases: whether we have created a good specification and functional characteristics list, selected the right components and designed the PCB in accordance with the design requirements. Careful testing is therefore an essential part of successful PCB prototype production.
The key is to carry out testing so that any deficiencies can be identified and corrected before the product is placed on the market. Remedying problems at this stage is always cheaper than withdrawing products from the market for servicing or completely replacing them with new products. It should also be said that a project should always allow for two or three hardware revisions, during which the product’s shortcomings are gradually debugged. We cannot therefore assume that we will be able to bring the first prototype to market immediately. Such planning of project economics would certainly be doomed to failure.
Certification
If the relevant general legal provisions require certification for the product, or if the customer requests it, the certification process is carried out by accredited laboratories after testing. Certification is an important part of PCB prototype production, as it helps verify that the final prototype meets the required safety, quality and regulatory requirements.
In the case of low-voltage electronic equipment, the law requires the manufacturer to assess the conformity of the equipment in accordance with Government Regulation No. 118/2016 Coll. Conformity is then most often assessed according to the selected harmonised standard that is most appropriate for the product in terms of its content and classification.
The manufacturer may also choose a method of conformity assessment other than using a harmonised standard. In this case, however, it must sufficiently demonstrate that the equipment meets the relevant legislative requirements. If the legislation does not require testing in an accredited laboratory for a particular product, it is sufficient for the manufacturer to demonstrate that the equipment complies with the applicable requirements. For reasons of certainty, the customer may request testing by an accredited laboratory. However, such tests can be very expensive, and the cost is incurred in both successful and unsuccessful cases.
Pre-Tests According to Standards
If you encounter a non-conformity with the standard during accredited testing of a third prototype, you may be forced to redesign the product. It is therefore advisable to carry out pre-tests against the relevant standards from the first prototype as part of internal testing. Early testing is particularly important in PCB prototype production, as identifying problems at this stage can prevent costly redesigns later.
Many accredited and non-accredited laboratories allow such assisted pre-tests. Thanks to pre-tests, non-conformities with the applicable standards can be addressed from the very beginning of development. Accredited testing should then be carried out only when the equipment has successfully passed all relevant pre-tests. This approach can significantly reduce risks and improve the efficiency of PCB prototype production.
However, product testing is not governed solely by legal provisions. The product can be tested and tested to any standard as required by the customer. The compliance of a product with any required standard should always be verified during development, rather than at the very end of the process. This is particularly important for PCB prototype production, where identifying problems early can prevent costly redesigns and delays later in development.
Preparation for Mass Production
Successful testing of the device brings us to the stage where development is complete and all that remains is to prepare the documentation for mass production of the device.
The goal is always to make series production as efficient and cost-effective as possible. However, if we start preparing for mass production only at this stage of the project, we may discover that the equipment is not ready for series production. A costly redesign involving several development phases, including testing, could then follow. Proper PCB prototype production helps identify these potential problems before the product enters mass production.
Preparing for Mass Production from the Analysis
Preparation for mass production should begin during the initial analysis and continue throughout the development of the equipment. During individual development reviews, we can focus on shortcomings related to mass production and prepare the equipment so that it is ready for mass production at the same time as final testing.
The main goals of effective preparation for series production are:
- minimizing the number of production operations,
- minimizing manual operations,
- maximizing automated machine operations.
If manual operations are necessary, we should try to minimize the workload of the operator.
Installation Must Be as Simple as Possible
Already when designing the concept of the device during the analysis phase, we should keep in mind that assembly and installation should be as simple as possible. We design the equipment to minimize the number of mechanical parts, circuit boards and fasteners.
We decide where to route the wiring harnesses and where to place the connectors. We consider what mechanical and electrical fixtures will be needed during the manufacturing process. Last but not least, we consider how software and production data will be uploaded to the device. In the next phase of development, we then ensure that SMD and THT components can be assembled as efficiently as possible through appropriate PCB design.
Using test points on the PCB, we can prepare for automatic or semi-automatic product testing. We verify individual production processes during PCB prototype production and adjust them based on feedback from our own production or an external manufacturer. After testing and certification of the final product revision, the remaining work should consist primarily of preparing the final production documentation. This includes the BOM, drawings and work instructions.
Placing the Product on the Market
By securing mass production, we have reached the end of the entire process of developing and manufacturing the electronic device. The final product can now be brought to market and delivered to customers. In the three parts of this article, we have briefly summarized the economics of developing and manufacturing electronic devices, including the role of PCB prototype production in the overall development process.
However, this area is very broad. Many topics and details could not be covered in detail due to the size of the article and can be addressed separately in the future.
Conclusion
This three-part article does not contain a complete list of material and manufacturing items and costs that would allow the development and production of any electronic device to be calculated precisely. Each device is unique and can vary considerably in complexity. The purpose of our series of articles was primarily to highlight the fact that if you want to successfully bring a new electronic device to market without suffering significant economic losses, you must carefully evaluate:
- what device you want to develop, based on its functional features,
- what resources and technologies you need to develop and manufacture it,
- how PCB prototype production will fit into the overall development process.
You also need to understand the different development phases and manufacturing processes that the device goes through during development and production. If you want to optimize the costs of the different development phases in your project costing, you must always be guided by the functional characteristics. You must also consider which areas can be optimized and which cannot.
Last but not least, you must carefully and honestly consider whether you have sufficient material, production and personnel resources to compete with the product in the market in the long term. If you are not able to provide long-term mass production, service and technical support after the market launch, you will soon risk losing the confidence of your customers.
Do you have an idea for a new electronic device that you would like to bring to market, but are concerned about the entire development and design process? Contact ASN Plus and let us know your thoughts and ideas. We will guide you through the process, alert you to potential pitfalls and take the necessary steps if you wish. We’ve helped bring a number of electronic products to market, and we’d be happy to lend a helping hand to you.