Product Life Cycles and Sustainability

1. Product Life Cycles and Sustainability 34% 34% 2% 2% 14% 14% -2s -3s +2s +3s -1s m +1s

2. Product Life Cycles • Concept • Design • Manufacture • Shipment and Installation • Warranty Period • Useful Life • Failure and Repair • Disposal

3. Product Life Cycles • Concept • Design • Manufacture • Shipment and Installation • Warranty Period • Useful Life • Failure, Service & Repair • Disposal Traditional Design Eng Focus Traditional Mfg Eng Focus

4. Product Life Cycles • Concept • Design • Manufacture • Shipment and Installation • Warranty Period • Useful Life • Failure, Service & Repair • Disposal Traditional Design Eng Focus Traditional Mfg Eng Focus Life Cycle Product Focus

5. Customer Labeling: User Manual • Product Specifications • List Product Level Capabilities/Functions • Performance Requirements • Standard Requirements • Must Include Environmental incl Temperature, Humidity, etc • Must Include Mechanical Dimensions, Mass, Shock, etc • Control Inputs • Outputs including Displays • Interfaces including precise definition of connectors, signals • Complete Description of Operating Modes • Button or Menu Sequences for Clarity

6. User Manual • Safety and Regulatory Certifications • UL Safety Standards • IEC and CISPR EMC Standards • User Warnings • Limitations of Product by Demographics, Geographics • Cautions and Warnings • Compatibilities or Incompatibilities • Specific Label Applications or Misapplications • Safety Rules

7. User Manual • Installation • How do I install the product? • Operation …..How do you use the product? • Step Method (used for simple products) • Step 1, Step 2, …. etc • Menu Method • Show how to move to any given mode • When in mode, show all user screens or displays • Show/Describe all Possible User Inputs • Describe all Possible Outputs/Displays user may see

8. User Manual • Maintenance • Specified for a period of calander time, operational time or number cyclic operations • Describes what is to be calibrated, checked, replaced, etc • Test Procedures, Calibration Procedures, Replacement Procedures • Typical Replacements Include • Batteries • Sensors • Filters • Mechanical Wearout Components such as drive belts, pulleys, etc • Manual Section should show picture and textual replacement steps • Manual should indicate who should perform the maintenance (authorization, training level, etc) • Relationship to product warranty

9. User Manual • Service • Specified for repairs above and beyond normal maintenance • Service Strategies Include (Select 1 or more) • Field Repair by User • Requires service manual and replacement part depictions • Requires a concise list of replacement parts and procurement • Specialized Service Center • Requires specific replacement parts list • Specific testing equipment and skills • Factory Repair or Replacement • Still Requires replacement parts list documentation • Requires repair process chart (mimics mfg test processes) • Assembly/Dissassembly • Default-Disposal • Requires disposal strategy, No repair strategy • Must identify specific disposal procedures for ALL batteries

10. User Manual • Warranty (From Previous Lab) • Specified for a period of time or number of operations • Must specify how to exercise the warranty • Teams should show (in ppt slide) relationship between warranty period and reliability calculations • Reliability analysis yields F(1 warranty period) = % of population that will fail within 1 warranty period. Assign Cost/Failure. • Warranty Costs = $ Cost of Failures << 1% of total sales • MTBF under simplified conditions indicates when ~63% of population has failed. In general, Warranty Period << MTBF

11. User Manual • Other Sections/Elements • Digital Pictures • Ideal for Describing User Controls • Assembly/Dissassembly, Exploded Views • Correct operational waveforms • Common Troubleshooting • Problem/Symptom • Cause • Corrective Action

12. Sustainability Aspects: Obsolescence • Standardized Industry Life Cycle Definition • Standardized Statistical Prediction Tool • Component Life Parameters, u, s • For any given part you must consider; • Part Type and Functionality • Manufacturer(s) and number of sources • Part Technology and Process • Part Package

13. Sustainability 6 Std Component Production Life Phases Rate of Production • = Mean (Max) Sales of Unit Components per Unit Time s = One Standard Deviation in Production/Time or Sales/Time

14. Production Life Cycle of a Component • Special Histogram of Production as Measure by Component Sales/Time (# shipped/time) • Concept Assumes Component Sales follow monotonically increasing to peak, then monotonically decreasing to obsolescence • Life Cycle is Measured Relative to Peak of Sales • +/- 1s from Peak = Mature Product • -1s to –2s from Peak = Growth Product • -2s to –3s from Peak = Introductory Product • +1s to +2s from Peak = Declining Product • +2s to +3s from Peak = Phase Out Product • +3s and higher from Peak = Obsolete Product

15. Statistics Application: Production Life Cycle of a Component Recall Area under curve = Percent Probability 34% 34% 2% 2% 14% 14% -2s -3s +2s +3s -1s m +1s Characterized by Two Parameters m and s2 Normal Distribution = N( m,s2 )

16. Sustainability Life Cycle of Common Analog IC’s

17. Sustainability Life Cycles of Digital/Analog IC Processes

18. Sustainability Life Cycles of IC Process Voltages 2000 2010 2020 1980 1990

19. Sustainability Life Cycle Phases of IC Packages

20. Sustainability Discrete RC, SMT Package Outlook Decreasing Power Rating Dominant Package by Year

21. Sustainability Aspects: Obsolescence • For each applicable component in your block BOM, perform a variance analysis • 1st Consider the part type: Find the u+(2.5)s, u+(3.5)s dates • 2nd Consider any applicable attributes • 3rd For each attribute find the u+(2.5)s, u+(3.5)s dates • Find the worst case u+(2.5)s, u+(3.5)s dates • Use u, s in years • +2s to +3s from Peak = Phase Out Product • +3s and higher from Peak = Obsolete Product • Create a separate BOM table of obsolescence analysis with above data • ID all parts above the 2.5s, Separately ID all above 3.5s Formulate Corrective Actions or Risk Mitigations Note: If you have a component that does not fit any category, ignore it for this analysis

22. Requirements – Brief Review User Level Product Level Block Levels Definition: “Statements of desired product performances and features used to define and quantify a product design” • User Level: Special list or labels which state the intended application and/or purpose of the product (Labeling) • Product Level: Quantitatively state all features, performances, and interfaces described in “Eng Terms” • Block Level: State all features, performances and interfaces describing the block in “Engineering Terms” • User Level >>> Validation (User Testing) • Product & Block Level>>>Verification (Eng Testing) Effective Engineering means full verification of requirements !!

23. Recall Requirement Allocation and Association to Design Blocks • ALLProduct Level Requirements Must be allocated or associated to each Design Block within the project to complete a System Design Phase • Allocated: % of total budgeted to applicable design blocks plus margin. For example: Product Cost, Power Consumption, Mass …. • Associated: Used when allocation is not applicable. For example: Country(s) of Market, Annual Volume, Safety Standards ….

24. How Do I Show Requirement Verification ? • Inspection, Existence (Mostly Std Requirements) • User Manual (UM) • Product Labeling • Business Case • BOM’s, Asm Dwgs and other Eng Dwgs • Engineering Analysis (Mix of Std and Perf Requirements) • Analog Worst Case DFM Analysis • Digital Worst Case DFM Analysis • Circuit Simulations, Other Numerical Analysis • Lab Testing (Mix of Std and Perf Requirements) • Bench testing circuit performances using metrology • Mechanical Measurements • Integration with other design blocks, compatible equipment • HALT and Other Stress Tests for Reliability • Safety and EMC Testing

25. Objective Verification Evidence • Verification Plan • Numbered List or Numbered Table of ALL requirements • Corresponding List or Table of Verification Types • Location or Pointer to Verification Evidence File(s) or Doc(s) • Detailed Test Plan and Test Results Document • Use for All Simulation and Lab Test Verifications • Written with sufficient detail, a 2nd party could perform the testing • Must describe all inputs, permutations, configurations, and expected output limits • Test Results may be in a separate document in case multiple verifications will be conducted. Sims, Scope Traces, Digital Photos • Summary of Verification (Lab 10) • List Key Requirements and Verification Types Employed • List Any Requirements which were Unverifiable • Summarize Detailed Test Plan for Key Performance Requirements • Show % of Requirements Verified (Coverage)

26. Appendices

27. Sustainability Aspects: Appendix Component Life Cycle Data Table • DOI = Date of First Introduction to Market • Note: Based on actual data but ALL numbers may not be realistic

28. Sustainability Aspects: Appendix Component Life Cycle Attribute Data Table

29. Sustainability Aspects: Appendix Actual Study Data Example • Assume Microcontroller is Special Consumer • For Digital and other IC’s don’t use Type attributes Add 5 years to correct

30. Obsolescence Table Example • Sample calculations for a few suspect IC’s (Present Date p = 2000.8) • In this case, the present date was subtracted from the window points and any negative value means there is a potential issue