Methodology

Calnetix Technologies employs a comprehensive six-stage product development process to manage 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 enhance the value delivered. Customers are encouraged to and often participate in the development review meetings.

Phase 1:  Feasibility and Concept Definition

The concept design work is conducted based on the initial requirements from the customer and is completed within an agreed upon time frame. In this phase, design tradeoffs are typically conducted to come up with best possible design concept for the application. Performance and cost estimates, risk assessments and a compliance matrix are then prepared and presented to the customer for consideration. In addition, the initial project’s development plan including the scope of work split (engineering, hardware and integration), design verification testing plan, major project milestones, deliverables and project schedule are updated and discussed with customer in a concept design review meeting.

Phase 2: Preliminary Design and Review (PDR)

Further design iterations and analyses are completed along with an updated CAD model of the design to refine the design concept and to incorporate any additional information resulting from the concept design discussion in Phase 1. This process includes preliminary mechanical and/or electrical analyses that are conducted based upon the type of project. System and component interfaces must be defined and are followed with an in-person preliminary design review (PDR) meeting to discuss design and analyses results. Typically, action items are created and incorporated into the following phase.

Phase 3: Detailed Design and Review (DDR)

The findings of the preliminary design review are applied to the detailed design effort. These include system and component analyses, verification test plans, manufacturing plans and tooling designs, and product acceptance test procedures. Detailed component and assembly drawings of the design are prepared along with detailed integration information, such as mechanical and electrical interfaces, system level connections and associated controls. This phase concludes with a detailed design review (DDR) meeting. Action items developed during the DDR need to be addressed prior to moving to Phase 4.

Phase 4: Hardware Development

This phase is primarily focused on building initial units and preparation for testing. Overlapping with phase 3, phase 4 includes reviewing and ordering long lead items. Additional design iterations may be required, and all necessary drawings are updated or created to address any agreed upon improvements/changes. Tooling is designed and built, and work instructions and quality control plans are prepared.  Any subassembly testing and verification prior to final assembly of the product needs to be completed and documented consistent with the program requirements. A hardware build review is conducted to ensure all lessons learned during the build activities are captured and that documentation is updated to reflect the latest configuration.

Phase 5: Design Verification 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. The Test Readiness Review is conducted, and 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. The Test Results Review is held with the customer to review the test results validating and verifying every requirement from the Compliance Matrix.

Phase 6: Production Hardware and Support

A Production Readiness Review is held to ensure the products are ready to be released to production.  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.