Post on 21-Aug-2015
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ZebulonSolutions, LLC
www.zebulonsolutions.com
Productization
Definition:Productization is the process of transitioning products out of the R&D lab and into stable manufacturing
ZebulonSolutions, LLC
www.zebulonsolutions.com
About Zebulon Solutions, LLC
Founded in 2009 Acquired Technical Mandala, a Colorado design services
company specializing in electronics design, in 2012 2100 sq. ft. office / lab in Longmont, CO Global customer base
• From startups to billion dollar multinationals Team averages 20 years of industry experience with 100+
successful production launches under our collective belts
ZebulonSolutions, LLC
www.zebulonsolutions.com
Productization services
Design
Reverse Engineering
Industrialization
Supply Chain
Test
Redesign
Strategy
ProductionConcept
ZebulonSolutions, LLC
www.zebulonsolutions.com
Design
Zebulon Solutions can do the full design, take on a small piece or subsystem, or do the grunt work at the end to finalize the design. In all cases we do everything with an eye toward manufacturability, supply chain and cost. Design services:
• Concept design• Systems architecture and engineering• Detailed designo Electrical / Mechanicalo Software / Firmwareo Mechatronics
• Design finalization• Prototyping and pretesting• Design Failure Mode Effects Analysis (DFMEA)
ZebulonSolutions, LLC
www.zebulonsolutions.com
Redesign
Products often need to be redesigned for cost, functionality, or manufacturability reasons Cost isn’t the only parameter, but it is a big one Analysis
• DFx: Design for Manufacturing / Assembly / Test / etc.• Independent Design Assessment• Failure Mode Effect Analysis (FMEA)• Tolerance analysis
Redesign• Cost downs• Proactive or reactive• Board, subsystem or complete product
ZebulonSolutions, LLC
www.zebulonsolutions.com
Reverse engineering
Analyzing competitors’ products to understand performance, cost and supply chain. Teardown services include:
• Teardowns• Reverse engineering• Supply chain reconstructions
Teardowns can be used to analyze the competition, avoiding IP issues, and even to bring in buy subsystems
ZebulonSolutions, LLC
www.zebulonsolutions.com
Industrialization
Industrialization is at the core of productization, the optimization of the processes, testing and tools that will be used to manufacture the product Design validation testing
• Environmental and life testing• Regulatory and safety
Tooling Production test development Supply chain development Contract manufacturer selection Process optimization Process validation testing
ZebulonSolutions, LLC
www.zebulonsolutions.com
Supply chain
The supply chain should be designed into the product, not optimized after the design is complete
It’s called a supply chain for a reason Cost is only one piece of the puzzle. Other supply chain drivers:
• Where do the key components come from?• Where will the product be shipped?• Upside and downside volumes protection• IP risks
Supply chain services:• Supply chain setup• Qualifying vendors• Selecting manufacturers
ZebulonSolutions, LLC
www.zebulonsolutions.com
Test
A test strategy is needed early on• Where, when, how, and especially why to test• Tradeoff upfront DVT testing vs. ongoing production testing• Subsystem level test also needs to be considered
Test services• Design validation testing (DVT)oPretestingoProgram manage full DVT
• Production test developmento Test requirements generationo Test system developmentoGauge R&R
ZebulonSolutions, LLC
www.zebulonsolutions.com
Process optimization
PVT is way too late to start on process optimization… The cost of process change for medical devices is
extremely high Process development should commence all the way back
in the design phase Use PFMEAs to find issues Product specific Use pretesting to find
issues Supply chain needs to be
taken into account tooCourtesy of Vergent Products
ZebulonSolutions, LLC
www.zebulonsolutions.com
Design For Excellence (DFx)
DFx is a key part of productization, but it needs to be done concurrent to design, not as a checklist after the fact DFx covers all the design fors:
• DFM: Design for Manufacturing• DFA: Design for Assembly• DFE: Design for Environment• DFT: Design for Test• DFT: Design for Regulatory• Etc.
DFx should be baked into the process But it also helps to have an extra set of eyes
ZebulonSolutions, LLC
www.zebulonsolutions.com
Process Validation Testing (PVT)
While regulatory requirements tend to drive PVT for medical devices, there are more mundane issues to address as well A device may indeed be certified on a process that is certified and
still be problematic, expensive or both Process validation is more that just “run three batches” Issues to consider (and solve):
• Yield• Early failure detection• Costs• Labor content• Throughput• Inventory stacking up
Courtesy of Vergent Products
ZebulonSolutions, LLC
www.zebulonsolutions.com
Other productization tasks
Product redesign for manufacturability / assembly / testability
Manufacturing strategy development Cost reduction redesigns Contract manufacturer selection Packout design and testing Software / firmware testing
ZebulonSolutions, LLC
www.zebulonsolutions.com
Strategy
Zebulon Solutions complements its hands-on engineering and supply chain expertise with big-picture strategic consulting and even fractional executive services
ZebulonSolutions, LLC
www.zebulonsolutions.com
Example: Inventory Management System
Scope: Strategic manufacturing
consulting Fractional VP of
Engineering Failure analysis Manage regulatory testing Status
• Supporting investor discussion this week
• Ongoing strategic support Future tasks
• Complete redesign• Supply chain optimization
ZebulonSolutions, LLC
www.zebulonsolutions.com
Example: In-line Analytic Instrument
Scope: Design of all PCBAs Electronics systems
engineering PCBA testing and
prototyping Status
• Ongoing testing• Redesign in
progress to add new features
ZebulonSolutions, LLC
www.zebulonsolutions.com
Example: Optical Touch Panel
Scope: Fractional VP
Engineering for 9 months
On-site systems engineer
Electronics / firmware optimization
Tolerance analysis Production test
development Status
• Unfortunately the customer went Chapter 7
ZebulonSolutions, LLC
www.zebulonsolutions.com
Example: Cleantech Flow Battery
Scope: Strategic
manufacturing consulting
Process optimization Supply chain
optimization Generated and
managed RFQ process to select a contract manufacturer
Status• CM selection within
two weeks Future tasks
• Manage NPI process
ZebulonSolutions, LLC
www.zebulonsolutions.com
Example: RV Aftermarket Accessory
Scope: Teardown of
electronics subsystem• Developed skeletal
BOM• Costed out the BOM
Tested system to recreate performance specs• Electronics• Firmware
Status• Testing in progress
Future tasks• Rewrite software• Redo PCBA design
ZebulonSolutions, LLC
www.zebulonsolutions.com
Example: Baby Product
Scope: Started as design
finalization• Added draft to plastics• DFM analysis
Expanded to include • Extensive pretesting against
ASTM safety standards• Redesign of key components• Generated 2D drawings and
complete BOM• Qualified offshore tool shop
and molding operation• Managed the tool builds
Status• In production
ZebulonSolutions, LLC
www.zebulonsolutions.com
Example: Satellite Internet
Scope: Teardown 8
satellite internet systems
Includes 26 GHz technology
Developed:• skeletal BOMs• block diagrams • process flows
Provided analysis Status
• Complete
ZebulonSolutions, LLC
Thanks
For more information on productization, see our productization blog at
www.zebulonsolutions.com/productizationblog/
www.zebulonsolutions.com