Firmware
Software for the electronics is often 50% or more of the design work in a project. The programming that controls the microprocessor usually gives the electronic product its features and "glitz" whereas the hardware is the purely functional side of the equation. The programming or coding for electronic products is usually written in 'C' or assembler, whereas the programming that runs on a PC will normally be written in C++, java or another language (and almost certainly not assembler). The programming for microcontrollers is totally different from that for a PC in any case - it is usually "more detailed" and less "generic" than the type of programming made for a personal computer, because it is more tightly coupled to the electronic hardware on which it runs, and because it usually has to respond more quickly - that is it has to run in "real time". There is usually a great deal of care and testing involved with programming for electronic products - while for some reason clients seem willing to accept bugs in windows software as somewhat normal, they are pretty unacceptable in, say, an engine control unit for a modern car.
The firmware may be developed by a separate team, and it is at the prototype stage that the two projects come together. (See: More info - Firmware) When the two components are integrated and prototype testing is complete, the finished project is handed over to the customer.
Pilot Run
To test the product further, a Pilot run normally follows the prototyping stage (See: More info - PCB Assembly). In the Pilot run, a small quantity of units (for instance 25) are field trialed in a beta test. The Pilot run is also an opportunity to assess the manufacturability of the design, and the useability of the documentation (See: More info - PCB Documentation).
Production
Following the pilot run there will likely be changes to the firmware, and possibly the circuit design, as the unit develops into a stable, final product. This process is controlled by ECOs and version numbers. We handle the actual production of electronics for some customers, but others prefer to produce the circuitry in house, or use other assembly subcontractors. Our technical documentation is sufficiently detailed for our customers to have the electronics produced by a third party subcontractor. The cost of the final production, and to some degree the style of design, is heavily influenced by the number of units manufactured (see Economies of scale).
Innovation and Inspiration ... an opinion
For five seconds you're a genius, the rest of your life a bum. Write it down. -- Lawrence Miller
Inspiration - Why have we left this until last? We all know it has to come first! The electronic design process can be methodical, almost mechanical, but the creativity at the start uses a very different set of human qualities. Throughout the high-tech business world the most amazing success stories are of inspired people, not large bureaucratic engineering departments with efficient Total Quality Management. (No offence intended - we work to standards ourselves)
Creative aptitude is really important in making new technology products come to life, and also in identifying the market and the need the product will fill. The ability to bring that inspiration through into a final product requires the level-headed decision making. Some electronic designs are not really new products as such, but developments of existing products. These designs, also, require creative vision to see which new features are really the most desirable, and how the design can be economically produced.
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