In this article, Robert John Webber, Applications Director for Europe at Powell Electronics, a distributor specializing in high-reliability connectors, outlines 10 design tips and techniques that help eliminate unnecessary time pressures, avoid delays, and shorten time to market.
Team organization is fundamental.
The first task for any company or organization involved in the design, development, and manufacturing of devices and products is to build a good team and organize it effectively. Typically, a project manager leads a multidisciplinary team of engineers with the various specialized skills required, such as software, electronics, mechanics, printed circuit board design, manufacturing, and quality control. Proper team organization is especially important for large teams or when members work remotely.
A good analogy is a sports team. In every sport, the coach (i.e., the project manager) must help build and coordinate a team made up of people with diverse skills, roles, and responsibilities. These skills, typically possessed by people who know their jobs well, must be leveraged to bring out the best in everyone and achieve the project's objectives. A team without the right mix of skills and abilities, or with the wrong coach, will not perform well.
How to cope with adversity.
The last few years have been tough for everyone in the industry due to several challenges that have made it increasingly difficult to develop the business: from Brexit and US-China trade tensions to the COVID-19 pandemic and the war between Russia and Ukraine. Even before these disruptions emerged, supply chains were under pressure due to the demand for new technologies, increasingly tight development cycles, and just-in-time production.
Some manufacturers struggled during the early months of the COVID-19 pandemic because their processes weren't flexible or resilient enough to cope with the various disruptions, as some suppliers closed or rejected orders. Between workplace issues, affected and dispersed workforces, and severe supply chain problems, some companies were unable to continue operating and therefore ceased business temporarily or permanently.
A house can't be built without bricks.
Supply chain and sourcing issues are among the most serious challenges a manufacturer faces because even the best team can't produce a product without its components. One of the first questions to ask yourself is: When do I need components in stock? Do I need them for production or for prototypes? When and how many are needed is crucial because, while components for a prototype can often be obtained, they may not be available in large quantities.
Understanding and managing lead times is a critical element of modern manufacturing. It is vital to ensure that the necessary lead times for components are factored into your development plan and schedule. Before the COVID-19 pandemic, component lead times could be expected to be around four to six weeks, but now these lead times can range from 26 weeks to over a year, depending on the component.
Longer lead times (or worse, unavailability) can derail a project. In a typical pre-COVID development workflow, after the initial concept phase, sample components could be used, from design and prototype development to initial testing. The findings could then be incorporated back into the design and further development before formal testing, based on application requirements and regulatory compliance. At this stage, bulk component orders are placed, and production begins.
Currently, every step must be taken with great care. Initial development should be carried out using a Design for Manufacture (DFM) methodology, with specifications based on component availability and performance. Alternative components should also be assessed at each stage, especially for those known to be in short supply. This is where it becomes vital to engage a trusted development partner with extensive knowledge and experience in supply chain management.
For example, a qualified development partner can help you select components, determining which ones can be replaced with few or no technical issues. Maintaining close communication with the partner is also crucial, as critical product deadlines can be shared throughout the development process. Furthermore, it's important to leverage existing assets to ensure the bill of materials (BoM) is flexible enough to accommodate any design changes.
10 Tips for Success
1. Ask for help reviewing the bill of materials: Qualified development partners can help you select the right components and avoid common mistakes. For example, the choice of connector plating might significantly impact lead time, but does it make a noticeable difference to your design needs? Harwin's M80-5401622 PCB connector has gold in the contact area and tin/lead on the ends (lead, often used in MIL-SPEC applications, helps prevent tin stranding), but its current lead time is 14 weeks. A quick chat with a field application engineer (FAE) might reveal that the M80-5401642 connector (identical in every way except for the tin ends) is perfectly suitable for your application needs, saving you 14 weeks because it's readily available from stock.
2. Engage FAE (Facilitator Equipment Experts) for specification assistance: FAE and product specialists can provide specifications, 2D or 3D drawings, test reports, pricing information, and certifications, especially for legacy components and when the component database is limited. This can streamline the process and prevent future problems.
3. Communicate critical product dates: It is vital to communicate key development and project dates. Good distributors can alert you to potential supply chain issues around these dates. Open communication sometimes allows for order protection, anticipation, or scheduling with suppliers.
4. Component selection: To prioritize, select your components based on i) their ability to solve design problems (technically); ii) project dates; and iii) manufacturability.
5. Use multiple suppliers: Different suppliers will have different technology offerings, stock levels, pricing models, and customization options, so this approach provides the optimal solution from both a technical and commercial perspective. For example, Glenair and Harwin offer highly reliable interconnect components, but their supply models differ. Glenair specializes in customized products and offers very short lead times, but its price may be higher for small orders. Harwin, on the other hand, focuses on widely used versions, and its lead times are average for the market, which helps it maintain competitive pricing.
6. Maintain a flexible Bill of Materials (BoM): Traceability is important, and one problem that has arisen as a result of standard component lists is that they limit alternatives or cross-referencing possibilities. However, if you can maintain a flexible BoM to change components during development phases, this can help mitigate some supply chain issues.
7. Don't limit yourself to your usual suppliers: Considering alternatives to your usual suppliers can also be helpful.
8. Leverage distributor warehouses: Some distributors can help you manage your just-in-time delivery requirements by holding stock for you and delaying delivery.
9. Share solutions: Using the same components in various solutions whenever possible allows you to use fewer product lines, which reduces the likelihood of stockouts and enables you to take advantage of better pricing for large orders.
10. Reduce the number of items in the Bill of Materials (BoM): Custom kitting and wiring products can facilitate this by reducing complexity and improving delivery.
Powell maintains strong partnerships with a large number of manufacturers and suppliers. However, in the current environment marked by component shortages and long lead times, the company has expanded its portfolio of represented brands with alternatives that can shorten lead times across several product categories. These include KEC with its EMC interconnect back covers, Corning with its specialized RF connectors, Hi-G with its relays, Altran Magnetics with its DC contactors, and East Coast Microwave with its custom RF cabling products. The company has also increased its investments in high-demand products with its existing partners; for example, in its stock of Amphenol components and Glenair heat shrink tubing.
Looking to the future
, surviving and thriving in today's uncertain geopolitical and industrial environment demands effective management of both your team and supply chain. Achieving the optimal team composition can help address problems before they arise, ensuring the right people are in the right roles and can communicate effectively. Your sourcing should include selecting components based on how well they technically solve the design problem, how well component availability fits your project timeline, and the manufacturability of the resulting solution. Working with qualified development partners allows you to address all these factors effectively and mitigate supply chain challenges and issues.
