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Phase 1
 

Defining the specifications (high level)

The customer needs to let us know the functional needs, the typical use cases, etc. (depending on the product). 

  • We typically
  • Ask a lot of questions and point to some technical difficulties that can already be predicted
  • Point to the major risks, all the way to mass production
  • Research compliance requirements
Phase 2
 

Feasibility / Proof of Concept

The content of this phase varies widely depending on the project. The purpose is to address the main assumptions and confirm the product can actually be made and can work as intended.
  • We typically
  • Work on important decisions such as the selection of materials, components, and technologies
  • Source the components and estimate the cost & timeline, all the way to production
  • Develop a first (‘proof of concept’) prototype to confirm certain hypotheses
Phase 3
 

Prototyping

We complete some of the design work and go through the prototyping iterations. It is a rare product that is simple enough for its first prototype to be “just right”.

  • We typically
  • Order the necessary parts
  • Assemble the parts into a full prototype
  • Test the prototype and provide a full report
  • Design for Manufacturing (In case design is done by another 3rd party)
Phase 4
 

Tooling

Many of our projects involve a lot of non-recurring engineering, for example molds for mechanical parts.
  • We typically
  • Get molds and other tooling made, until it's signed off
  • Order tools and sign off on those samples
  • Assemble and test the final prototype
  • Arrange reliability tests, certifications, etc.
  • Confirm the quality standard and related checklists
Phase 5
 

Pre-Production Preparation

There is still some work before we can start making the final product. If we just buy material and give it to untrained operators, it usually leads to a quality disaster. All sorts of issues, which were not foreseen in risk analyses, may appear once products are made and tested using mass production processes.

  • We typically
  • Define the assembly & packing process, and the inspection & testing processes
  • Prepare the tooling and stations needed to ensure smooth assembly and testing
  • Do a pilot run, to catch issues before any large quantity is made
Phase 6
 

Mass Production

This is the time when you (the customer) can start to deliver products to your customers. We are happy making smaller batches at the beginning, and iterating and ramping the volumes up quickly, as needed.

  • We typically:
  • Order materials and conduct incoming QC inspections
  • Do the assembly, testing, and packing work, and share our QC findings with the customer
  • Ship the products out

Estimates, quotations, and payments

At the start of every phase (see above), we estimate the amount of work and other expenses (if any), and we provide a quotation.

We like to cut the work into relatively small blocks, phase by phase. There is a simple reason for this. As we complete one phase, it determines and clarifies the content of the next phase. That’s why we re-estimate the amount of work of the following phases each time we complete one phase.

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