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

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

3. Shipment and Installation Warranty Period Useful Life
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. Shipment and Installation Warranty Period Useful Life
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. 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

6. 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

7. 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

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

9. Sustainability Life Cycle of Common Analog IC’s

10. Sustainability Life Cycles of Digital/Analog IC Processes

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

12. Sustainability Life Cycle Phases of IC Packages

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

14. 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

15. 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 !!

16. Recall Requirement Allocation and Association to Design Blocks
ALL Product 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 ….

17. 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

18. 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)

19. 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

20. Safety and Regulatory Certifications
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

21. Operation …..How do you use the product?
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

22. 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

23. 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

24. 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

25. Other Sections/Elements
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

26. Appendices

27. Sustainability Aspects: Appendix
Component Life Cycle Data Table
Component Type u s
Applicable Attributes
Notes
Amplifier
2004.5
8.3
Technology, Package
Comparator
2003.0
11.1
Technology, Package, Voltage
Voltage Regulator or Reference
2004.0
6.5
A/D or D/A Converter
2001.5
7.8
Interface
2002
8.1
Specialty, Consumer
8 Bit Microprocessor
1990.5
9.2
16/32 Bit Microprocessor
1994.5
7.0
Memory
X+4
5.0
X = DOI
PLD
X+6
6.0
Carbon Resistor
1985
8.5
None
Metal Film Resistor
1990
12.0
Ceramic Capacitor
14.0
Other R, L, C’s
10.0
Battery, Power Plug (AC-DC) or Transformer
Speaker, Mic, Display, Camera, or Sensor
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
Process Technology u s
Comments
Bipolar
1975.0
12.5
NMOS
1986.0
8.0
PMOS
1968.0
8.5
CMOS
2010.0
BiCMOS
1997.0
4.0
Package
DIP – Dual Inline Package
1987.0
7.8
Thru Hole
SOP – Small Outline Package
1995.0
6.5
1st Gen SMT
CC – Leadless Chip Carrier
1996.5
4.5
2nd Gen SMT
PGA – Pin Grid Array
1997.1
QFP – Quad Flat Pack
1998.5
4.2
MCM – Multichip Module, All Other
1999.0
5.6
Process Voltage
5V and Above
1992.5
5.3
3.6V
3.0V, 3.3V
2.5V
2004.0
3.6
1.8V
2007.0
3.2

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

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