Methodology

Calnetix Technologies employs a unique six-stage product development process to manage and schedule our customer system integration projects.  Each project is unique and requires individual attention to estimate the project timeline and schedule.  In the spirit of continuous improvement, following a project’s completion, the project team meets to review the entire process and evaluate the product for ways to improve the value delivered. Customers are encouraged to be involved in this review process.

Phase 1: Project and Concept Definition (Feasibility)

The project’s initial system concept and requirements, roles and responsibilities, scope of work split (engineering, hardware and integration), validation and verification testing, major milestones, deliverables and schedule are defined during two days of in-person meetings using the original specification and project proposal to frame discussions. Once definitions are agreed upon, the concept design work is completed in a one to two month time frame. Various performance, cost and system tradeoffs are presented for each of the best concepts, and the concept design features that best meet the end system goals are selected during a one day design review.

Phase 2: Preliminary Design and Review (PDR)

Further design iterations and analysis are completed along with a 2D subsystem drawing over a three month time frame. This includes preliminary electromagnetic, thermal, stress, rotor dynamic, physical integration and other analysis to refine the concept design into a subsystem design that will be close in layout size and performance to the final design. A one to two day in-person preliminary design review (PDR) meeting completes this phase.

Phase 3: Detailed Design and Review (DDR)

The findings of the preliminary design review are applied to the detailed design effort over a three to five month time frame, which includes system and component analyses, test plans and draft procedures, manufacturing drawings and plans, and product support plans. Detailed 3D drawings of the subsystem are prepared along with detailed integration information, such as expansion/contraction, system level connections, configurations, interface and controls. Final material selections are made, and machine tolerances are evaluated. This phase concludes with a one to two day in-person detailed design review (DDR) meeting.

Phase 4: Preproduction (Prototype) Hardware Development

Overlapping with phase 3, phase 4 includes reviewing and ordering long lead items. Following phase 3, additional design iterations may be required, and all necessary drawings are updated or created to address any agreed upon improvements/changes. Work instructions are created to fabricate the preproduction system.

Phase 5: Preproduction (Prototype) Testing and Qualification

Component and system test plans are finalized, and test procedures are developed and jointly approved. Test responsibilities and any third party certification or oversight are agreed upon and scheduled. Once performance validation is approved on the component and subsystem level, system level validation testing begins. Calnetix supports the initial subsystem setup and commissioning at the customer’s facility as well as the training and assistance required for field evaluation. This phase typically takes one month to complete.

Phase 6: Production Hardware and Support

If needed, design changes are completed to further refine the system for production hardware, and any further testing is scheduled to verify the changes. Production units are fabricated based on the final production design and are tested in accordance with approved test procedures. If needed, changes are made to the production tooling and setups based on the production volume forecast. The product support plan is updated to include any changes in hardware as well as considerations for spares, training, maintenance levels, manuals and other implementation plans.