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The presentation I gave during a TMC Electronics pizza session in 2011. It describes the outsourcing proces we used during a project at Philips Healthcare in 2009. If you like or dislike anything or want to talk about hardware outsourcing. Contact me via twitter http://twitter.com/jhaand
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Designing the Cocoon Box outside the Box
Jelle Haandrikman
23rd February 2011
TMC Pizzasession:Outsourcing, everybody does it,but how to do it pragmatic
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About me
> Jelle Haandrikman
> jhaand
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What could possibly go wrong with outsourcing?
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This could go wrong
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The MD Eleva X-ray system from Philips
> Project
> Product
> Process
> Problems
> Conclusions
MD Eleva
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MD Eleva: Basic Layout
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Basic Architecture
Stand
Geometry
X-ray tube
Detector
30 m
30 m
Monitors
Ceiling
20 m
Power
PC
Geo Drive
X-ray gen
IP
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Project: DAM replacement
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Product: Cocoon Box (external)
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Product: Cocoon box (internal)
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Traditional outsourcing
White box and black box mostly don't work as intended.White-box: Outsource partner has invested in toolchain but no design transfer.Black-box: The local designer has a copy of design docs in his drawer.
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Process: Outsourcing / Co-creationin a nutshell
> Know what you want:- Which level of outsourcing → What kind of deliverable, scope of outsourcing.- High Level Design → High Level Specification.- Review → Add quality to the specification.- Rapid Prototyping → Validate the specification, get something to wrap your
hands around.> Outsource:
- Ask quotation → Takes time, but is give a good indication of rest of the development cycle.
- Agree on deliverables → It ain't over t'ill it's over. No last moment changes, or use change control.
- Collaborate → Although you're far apart, Communication remains crucial.> Finish:
- Validate → Did we get what we asked for. Does everything work?- Rework → Get the final nuts and volts right.- Archiving → We need to get everything back after 10 years of production.- Order → After a prototype, 1st of a kind and limited delivery. It's time for
regular delivery. (RfVLD)
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Process: What kind of outsourcing?
> What level of outsouring.
- Designed and engineered by PH, Built by Supplier
- Designed by PH, Engineered and Built by Supplier
- MOTS (Modified Of The Shelf)
- COTS (Commercial Of The Shelf)
> Who are you going to outsource to.
- Known partner (ask Manufacturing)
- Known supplier (ask Purchasing)
- Technology expert (ask Collegue)
- Company agreement (The project leader will tell you)
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Process: High level design
> Normal design process applies (eliciting requirements, visualising them, etc.)
> You use your own design process
> The supplier can use their own design process and documentation.
> The information with which you communicate is a lot more strict:
- Both parties must be able to write, read, process and archive it.
> The requirement specification:
- Keep it short ( =< 70 pages)
- To the point and on a need to know basis.
- Use as much references as possible. (Prevents requirement updates)
- More info: Course on requirements engineering or a good book on the subject.
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Know what's In-House or on the Market
> Re-use known parts: (cocoon: 24V power supply, Ethernet switch)
> Use the speciality of your possiblee partner (Kontron: Embedded PC's)
> Regular quality, cost, EMC, internal standards,
Obsolecence and Safety issues do apply. As an OEM, you remain responsible.
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Get it all in one specification
> Specifications should be set up the same as for a regular in house development.
> But add references to the “standard” In-house items to prevent making the specification too large or unmaintainable.
> Also take the follow up into account:
- Packaging
- Handling
- Testing (EMC, Safety, lacquer, bump and vibration)
- Service items
- Everything else during the life time of the project the outsource partner has to handle.
> For a high level specification: Bring all the necessary information, but don't take it too far, to prevent an overlap, double work or limit creativity.
> Engineering: The outsource partner will create engineering documentation.
> Review the specification.
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Peer Review the specification
> Peer reviews give the biggest boost in quality in early stages. Get most of the defects out in an early phase.
> CMMi standard peer review inspection is very effective, but also very heavy and slow. A formal inspection can take up to 2 weeks.
> Involve everyone:
- Other engineers
- Project leader (Moderator)
- Safety
- Manufacturing
- Service
- Possible manufacturers
> Rework the specification (takes time)
> Submit specification to archive after verification
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Rapid Prototyping
“Plan to throw one away. You will anyhow.” F. Brooks (The Mythical Man-Month)
> Get a feel for the product your designing, concerning manufacturbility, servicability.
> Do some testing (EMC, Power consumption, thermal behaviour)
> Let other disciplines see what your working on. (Software, System engineering)
> Preliminary test of your specification
> Tape, tie-wraps, nuts and bolts are your friends
> Outsource to the Workshop / Modelshop on-site.
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Supplier management
Customer Philips Supplier(s)
Specification
QuotationDeliverables
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Collaboration
Planning
< 24h
6 weeks
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Finishing Design and Engineering
TestingDeployment
Solve CR's and PR's Archive
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Outsourcing PCB's
BOM
Reqs
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Outsourcing Mechanics
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Outsourcing Cables
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Q: When not to outsource?
A: When it's not worth the trouble.
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Conclusions
Outsourcing saves effort and makes things possible you normally couldn't realize internally within your
organization.
>But:
- It still takes effort
- You have to explain everything to everybody.
>So:
- It will costs time and a lot of money
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And Finally....
Obsolecense handled by supplier?
On-site warehouse upgrade
How to take Outsourcing even further??
Train outsource partners???
Co-creation