Technical Machine's Hardware Playbook

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Technical Machine's approach to manufacturing. Learn more at http://tessel.io
Video of the talk: https://www.youtube.com/watch?v=0ZArxLefleg

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Technical Machine's Hardware Playbook

  1. 1. Technical Machine’s Hardware Playbook @jia | Jia Huang | co-founder & developer
  2. 2. Tessel is a WiFi-enabled microcontroller that runs JavaScript.
  3. 3. 15 electrical designs, $250k preorders
  4. 4. 2 manufacturers2 manufacturing locations MA, USA ● makes Tessel ● we manage most of the supply chain ShenZhen, China ● 14 modules ● higher overall volume
  5. 5. Tessel Timeline June July September December 2013 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. 6. Tessel Timeline June July September December 2013 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
  7. 7. Tessel Timeline June July September December 2013 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 15 designs
  8. 8. Tessel Timeline June July September December 2013 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 15 designs 1.5Hardware Engineers( )
  9. 9. Tessel Timeline June July September December 2013 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
  10. 10. This is how we do it.
  11. 11. 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
  12. 12. Engineering
  13. 13. Design / Prototype / Test First pass (~10 days) 1-3 days design 3 days PCB turn 1 day build 2-3 days test design review
  14. 14. Design / Prototype / Test First pass (~10 days) 1-3 days design 3 days PCB turn 1 day build 2-3 days test design review 7 days write test code
  15. 15. Design / Prototype / Test First pass (~10 days) 1-3 days design 3 days PCB turn 1 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/test design review
  16. 16. Prototype Manufacturers AP Circuits Alberta, Canada 3 day turns $10/sq inch KL, Malaysia 1.5 week turns ~$70+ ShenZhen, China 2.5 week turns $10/ 40 sq inches KL, Malaysia PCBA 3 week turns ~$300+ setup, $8/sq inch
  17. 17. Test Rigs Tessel tests Tessel Tessel tests modules
  18. 18. Test Plans
  19. 19. Test Plans ● Revision #s and dates
  20. 20. Test Plans ● Revision #s and dates ● contact info
  21. 21. Test Plans ● Revision #s and dates ● contact info ● Don’t assume English proficiency
  22. 22. Test Plans ● Revision #s and dates ● contact info ● Don’t assume English proficiency ● Have redundancy among test rigs
  23. 23. Test Plans ● Revision #s and dates ● contact info ● Don’t assume English proficiency ● Have redundancy among test rigs ● images
  24. 24. Test Plans ● Revision #s and dates ● contact info ● Don’t assume English proficiency ● Have redundancy among test rigs ● images ● setup info
  25. 25. 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
  26. 26. Supply Chain
  27. 27. Sourcing
  28. 28. Sourcing
  29. 29. Sourcing Online prices are fake. Find an inside sales guy.
  30. 30. Part Swaps Manufacturer should recommend swaps.
  31. 31. 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.
  32. 32. 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?
  33. 33. 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
  34. 34. 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 2. Find a drop in replacement
  35. 35. 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 2. Find a drop in replacement 3. There are none?
  36. 36. 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 2. Find a drop in replacement 3. There are none? 4. Do a redesign through the tears.
  37. 37. 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 2. Find a drop in replacement 3. There are none? 4. Do a redesign through the tears. Check errata documents ● Manufacturer only tests 1 axis of an accelerometer during production?
  38. 38. 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 2. Find a drop in replacement 3. 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.
  39. 39. Manufacturing
  40. 40. Getting a manufacturer 1. What kind of volumes? ○ <1k ○ <10k (Both China and America support these volumes)
  41. 41. 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)
  42. 42. 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)
  43. 43. 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)
  44. 44. 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)
  45. 45. 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)
  46. 46. China vs America Costs (sample size ~10 manufacturers) China Chinese with American office American American with Chinese office
  47. 47. China vs America Costs (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
  48. 48. Pre-production ● Quality ● Communication ● Test Process Do a pre-production run. (10+ units)
  49. 49. Production Put out fires.
  50. 50. Production Put out fires. Pray.
  51. 51. YMMV. https://tessel.io jia@technical.io @technicalhumans

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