NPI Phase 2
Engineering, prototyping, and design for manufacturing
Phase 2 of our NPI Process is a pivotal moment—this is where we begin optimizing your design for the manufacturing line.
Engaging all disciplines across our in-house engineering team—from mechanical design to electrical and firmware—we develop the product architecture and prototyping stage with experts onboard for every step. In this phase, we also ensure your design addresses all functional, cosmetic, and regulatory requirements.
Phase 2 sets the stage for a smooth journey into production.
Efficiencies at a Glance
- Upfront planning and testing helps us avoid sunk costs once production ramps up. If there’s a mechanical problem with the design, for example, we will find that out now.
- Documenting product requirements ensures the efficient transfer into the next phases, saving ample time and resources. For example, if a product needs to meet FCC requirements, we will consider this in the design phase, rather than going back to the drawing board later.
- Reviewing the PCB layout for any issues with trace widths, test point locations, component clearance for depanelization, etc. helps in optimizing and reducing costs for the final circuit board, while also preventing potential design failures during production testing.
- Finalizing a design that takes into account the manufacturing and assembly helps maintain the finished product's quality.
Determining The Product Requirements
The initial step of this phase is compiling your Product Requirements Document (PRD), a comprehensive blueprint that outlines the specifics of what the product should accomplish. In creating the PRD, we work with you to establish every granular detail of the product’s functionality, materials, and necessary steps towards compliance. By meticulously defining the product’s requirements, the PRD ensures alignment between stakeholders and minimizes ambiguities. It will also act as the guiding light for engineers as they work on design and development.
Note: Do you already have a completed design? We can meet you where you’re at by validating the work that has been done, and making recommendations where applicable.
Pre-Production Milestones
Phased Prototyping Process
Here our focus shifts towards the fundamental question, “what do we need, and by when?” Now we outline the necessary components and their timelines to smoothly transition from concept to production. Phased prototyping allows us to determine this outline.
This process works as follows:
- Looks-like prototype: Mirrors the design requirements, ensuring aesthetic accuracy.
- Works-like prototype: Aligns with functionality requirements, validating operational capabilities.
- Looks-like and works-like prototype: Integrates both design and functionality, for a complete validation of the product overall.
Product Planning
Incorporating expertise across industrial, mechanical, and electrical design, along with firmware development, we initiate the product's architecture. In this step we confirm everything is in order to start engineering the product and that all aspects of the design are evaluated for manufacturability. We ensure alignment with the set of requirements established in the Product Roadmap, encompassing all functional, cosmetic, and regulatory standards.
"Design for manufacturing is fundamental to successful hardware product development. Involving suppliers and manufacturing teams early in the design process allows us to optimize for cost, quality, and timeline, and ultimately deliver an excellent customer experience."
- Sarah Reymond, Director of Engineering
Product Improvements
We work with customers at many different stages of their product development journey–whether it be a new product, existing design, or second iteration.
As just one example, we are working on mechanical improvements to a personal safety device currently on the market. The changes will satisfy Reese’s Law, a new consumer protection legislation specifically for products with coin cell batteries.
Pitfalls Avoided
- When a Product Requirements Document is not done thoroughly enough, testing requirements can be overlooked.
- If new laws or regulations are passed during the product development process, working with a vertically integrated manufacturing partner gives you the ability to pivot faster to rework the design and maintain compliance.
- Design decisions made too far along in the process can mean going back to the hardware drawing board, resulting in sunk costs and extended timelines.
What's Next
At this point, we’ve established the product requirements, achieved the pre-production milestones, and laid the necessary groundwork. It’s no small feat, and the teams are feeling accomplished (for good reason). Plus, excitement is in the air as we gear up for Phase 3—this is when we will do tooling, purchase materials and components, and establish the processes to best manufacture your product.
Start the discovery process
Continue Along the Journey
Coming up next—Phase 3: Production Preparation and Supply Chain Setup!