Trouble in Paradise? Product launch delayed due to quality and cost?

To maximize market potential, you need to launch your products to the market on time and with the expected quality and cost.  How do you ensure that Your end customers are getting the quality they are expecting? How do you optimize your costs during the manufacturing phase, where high quality equals low cost?

When designing a new product, the need for a product specification is obvious to us all. At the same time, there is also a need to create a solid strategy and clear specification for how the new product should be manufactured and tested in the most efficient way.

Different product build concepts, or modularizations, might have very different impacts on manufacturing and test strategies. Where in the process flow should inspections and tests be made? What are the manufacturing and test methods and the possible product design requirements that result from the methods selected? How can we ensure that we are properly evaluating all possible properties to verify their measurements or functionality?

Adding new features and making late changes in an existing product or PCB design is much more difficult and time-consuming. Plus, those unwanted late changes are most often the root cause of project delays and increased project costs.

Co-creating value with design and manufacturing teams

A close interaction with your manufacturing partner is a must in order to secure that the project’s development is delivered on time and according to the project budget. The most important factors for the manufacturing and test set-up usually are already decided when you specify the functionality of your product, and definitely by the time product build concepts are decided and implemented.

There is therefore a need for close interaction between teams responsible for product design and manufacturing teams. Which components to select and the determination of the processes needed for manufacturing are directly related to:

  • The costs of material and assembly
  • The process-related defect risks
  • The efficiency of the inspection and test methods
  • The efficiency in test time for each product
  • How efficient you are in detecting possible defect risks

Different inspection and test methods each have their strengths and weaknesses. By analyzing the efficiency of different combinations and strategies of test and inspection methods, it’s possible to find out which inspection and test strategies will enable you to most efficiently reach the given target for delivering product yield. Initiating this process on the first release of the schematics can provide important input for design teams and aid in the future development and planning of product and PCB designs. In this way, when the first prototypes are designed, they will already include the features that are important for achieving the required level of testability.

As a manufacturing and test development partner, it’s essential to provide comprehensive services in this area. There are widely used DfT analysis tools that support this area of services. DfT analysis can give important feedback as early as the first schematic releases, and then be used to provide follow-up analyses when the product and PCB designs are made and finally completed.

Results from this strategy have shown that the number of PCB design iterations are minimized when manufacturing and testability needs are initially implemented in the original design. This has an important effect on achieving the desired project development costs and time schedules. Developing a solid product and conducting the right level of testing optimizes Your manufacturing costs and ensures a high level of quality in Your products, which is needed to leverage market opportunities.

Are you interested in more information on this topic?
If you would like to hear more, please contact our Test Engineering Department via (OEMs only)