China Manufacturing Decoded

Product Integration: Why Working Subsystems Fail When Assembled

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Your electronics work. The firmware runs correctly. The mechanical components fit, and every subsystem has passed its individual tests.

Then everything is installed inside the final enclosure, and entirely new problems begin to appear.

In episode 335 of China Manufacturing Decoded, Adrian is joined again by Paul Adams from the group's contract manufacturer, Agilian Technology, to explore one of the most difficult stages of hardware development: product integration.

 

Show Sections
  • 00:21 – When Individually Working Parts Fail Together
  • 02:28 – Why Everything Works During Bench Testing
  • 07:40 – What Changes When Integration Begins
  • 08:39 – Designing the Product So It Can Be Debugged
  • 10:16 – Integrating One Subsystem at a Time
  • 13:45 – A Technically Working Product Can Still Fail
  • 15:00 – The Hidden Impact of Heat Buildup
  • 20:19 – The First Complete Build Is Only a Mini Milestone
  • 21:39 – Solving an Enclosure Airflow Problem
  • 23:53 – Paul’s Product-Integration Playbook
  • 24:07 – Step 1: Integrate in Stages
  • 24:52 – Step 2: Test Important Risks Early
  • 26:16 – Step 3: Keep Debugging Access Available
  • 27:18 – Step 4: Test the Way the Customer Will Use It
  • 28:20 – Step 5: Treat the Enclosure as Part of the System
  • 29:29 – Final Lessons From the Integration Process

    •  

    Related content
    • How Many Prototypes Are Needed Before We Get ‘Perfection?’
    • Transitioning to Manufacturing from Product Development | 2 Options
    • Why does new product development take so long?
    • Typical Steps Before You Get Look and Work-Like Prototypes
    • An Effective New Product Development Process for Electronics
    • Final Prototype of your New Hardware Product: When Will You Get There?
    • Manufacturing Pilot Runs Are Great With Quantified Objectives
    • Handover to Manufacturing: What NOT to do & Best Practices

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