Sometimes we have to say No.

Saying No is an important part – a critical part – or our job as engineers and designers. Great products are designed by people who know when to say No and when to say Yes.

Great products do not need feature lists and check boxes. Great products are sold by their users because they love them.

You know what the most difficult thing about this is? You have to choose, and choosing means you have to be brave.

I just love this graph from Kathy Sierra and the article that goes with it (thanks for the inspiration).

"Give users what they actually want, not what they say they want. And whatever you do, don't give them new features just because your competitors have them!" – Kathy Sierra

There are a lot of steps to turn an idea into a product. Each step requires care and attention to ensure that the best product is created. Below is the process that I follow to create an electronic product. It is all laid out nicely in a linear way, but in reality a lot of the steps are occurring in parallel. Also, any step could be the starting point, it is really dependant on the product and client requirements.

1. Initial engineering report
   

   This is a short report which gives everyone some preliminary ideas to work from. I like to start with this as it is a small investment in testing the idea, and provides a lot of information for the path forward.

2. Detailed investigation
   

   The initial report or specification has already identified the options, now all the options are investigated in detail. This entails reading datasheets and application notes, speaking to distributors, and really understanding whether the available options will provide the required solution.

3. Development of proof of concept
   

   There are two ways to go here, either develop a proof of concept using evaluation boards, or dive straight into the custom hardware design – which is better depends on the risks involved. The risks are a function of the project and the amount of experience with similar designs. Wherever possible it is nicest to speed things up, but a detailed proof of concept can take a lot of risk out of the later stages.

4. Final concept
   

   After a full proof of concept it is quite clear how all the pieces fit together. At this stage we should have system block diagrams, communication protocols, component choices, disposal planning and a whole lot more down on paper. The framework for our creation is in place, now we need to make a real prototype.

5. Schematic layout
   

   All the concepts and ideas have to be put down into technical drawings (an electronic drawing is called a schematic). Once this is done we have a schematic, a BOM (bill of materials), and other technical files needed for the next steps.

6. Printed circuit board layout
   

   The schematic output is used to generate a printed circuit board (PCB layout). The physical size is determined and the components are placed and connected together with tracks. Any mechanical design which is required (e.g. a casing) is also done along side with this step so that the PCB will fit nicely. This can be a time consuming step, as a lot of checking is required, such as tolerances, spacing and component patterns. A set of gerber files are generated which are used to manufacture the actual PCBs.

7. Component procurement
   

   Before a prototype can be built, you need all the components that will be placed on the PCB. This step is really happening in parallel with all the other steps to ensure that everything arrives at the right time. Electronic component lead times can vary significantly (from 1 to 16 weeks or more), so a fair amount of planning and scheduling is required.

8. Prototype manufacturing
   

   A PCB manufacturer (such as WHCircuit or Trax) makes the PCB's according to the gerber files. The PCB is then populated with the components either by hand or machine. For a first prototype I like to populate the board by hand (where possible) so that I can test each part of the system as I build it up.

9. Development and debugging
   

   The amount of effort that goes into making a system work properly is really quite big, but depends on the complexity of the system and the amount of detail that went into all the proceeding steps. It must be shown that each block of the system works and that it all works together properly. Firmware (software that runs on the system) must be tested and developed to a fully functional level. Any bugs that are detected need to be resolved and noted for the future.

10. Testing
    

    Once all the functionality is working it must be fully tested, both to check that it is working correctly and to also stress the system to find out if any real world events could break things. Careful attention must be paid to test as many usage cases as possible, and more. Certain countries require specific certifications and any required tests must be done to ensure all the necessary specifications are met.

11. Design refinements
    

    All of the testing and development will either have proved that the design works exactly as desired, or indicated areas that need to be improved before going ahead with manufacturing. Steps 4 to 11 are repeated until the product meets the requirement.

12. Initial production run
    

    Manufacturing can bring its own challenges to the product from solderability through to the programming and testing of the product. To avoid major manufacturing disasters it is normally better to have a small initial run to iron out any problems in the process.

13. Product manufacturing
    

    Once all the manufacturing issues have been resolved it is time to go into full production. This can be a big investment and the quality of the work that has gone before will determine how successful the product is.

14. Continuous improvements
    

    There are always things to improve. Wherever possible I try to build in mechanisms that allow easy upgrading of products (such as in–field upgrading of firmware), but it is sometimes necessary to go through some redesign to meet a new requirement or fix a manufacturing issue. Once a product is out in the field you start to get a feel for how it is really used, which teaches you a lot about how to improve the quality.

It is a long process and is fraught with many risks, but the great reward of having created something meaningful which changes people's lives for the better is amazing.

If you are interested in creating electronic products, then please contact me.

Photo courtesty of Johannes Henseler and licensed under a Creative Commons license.

I am an advocate of making sure that every device consumes as little power as possible at all times. Indicator lights should be off, processors should be sleeping as much as possible, and generally the device should just be optimised to use as little power as possible.

I may have to rethink that....at least a little bit.

Dan Lockton has a brilliant blog, Architectures of Control, where he discusses how things are designed to result in a certain action (or lack of action) – or as he calls it, design with intent.

There are two devices in my home which have helped me to reconsider turning off all the lights, my DVD player and my laptop. Each has its own subtle "architecture of control" whether intentional or not.

Our DVD player has (to me) the most irritating standby light that I have ever seen on any device. When on, the light is constantly illuminated, but when in standby the light flashes continuously (at a slow rate). This drives me mad, but results in an interesting action – it causes me to turn it off at the plug when I am not using it (which is most of the time). Suddenly one little flashing light has resulted in more energy saving than having no light.

My laptop has a similar "feature." When it is powered down the battery indicator remains on (green if full, flashing yellow if charging). This used to bother me, and I thought, "Why not just leave the light off when the battery is charged?" My wife's laptop is like that, the battery indicator only flashes if it is charging, once charged it turns off.

That is all good, except my laptop communicates to me that it is plugged in and consuming standby power when it is not in use. When I unplug it from the wall socket, then the battery indicator goes off – I save the standby power of both the power brick and the laptop.

There is one problem with this, it only works on people who care. If I did not care about saving energy, then I would just leave the laptop plugged in and the DVD player on. That means that you have to consider how your users will handle this kind of subtle feedback and determine whether turning the light off, or encouraging unplugging results in more energy savings.

Sometimes the most obvious design decisions may not be the ones which result in the greatest energy saving. Keep designing for low energy consumption and also keep your mind open to new possibilities.

Engineer Simplicity....

....helps people turn ideas into products.

Your idea may be a new invention, a faster warehouse picking system, or a testing and debugging tool which makes your company run faster and better.

Bring it to me and together we will turn your idea into a great product.

The engineering design process

Problem → Idea → Concept → Design → Prototype → Refine → Produce.

In some ways that is really as simple as it is.

Changing a problem into a solution is a wonderful and rewarding process. It is about creating more value in the world around us. I often ask myself, "How does doing this make the world a better place?" By being true to that I can create (and help you create) truly great products.

Build a better way

I finally got around to watching "The Story of Stuff" and was absolutely blown away by the compelling and simple way that its message is presented. Spend 20 minutes of your time to watch this video (here, on the site, or download it)

It is really important that this message gets spread, as we all have a role to play in fixing what we have helped to create. As consumers we need to change how we purchase, as engineers we need to change how we create, as marketers we need to change the message that we spread.

There are some things we need to carefully consider. Take this comment from the brilliant Seth Godin,

"So I'm hoping that what you make is worthy. Marketing is a powerful tool especially when it associates a product with a desire and instinct we already have."

Does what we create help people to live a better happier life? Does it protect the precious world we live in? We have a great responsibility when we create, market and sell things – we need to make sure we carry that responsibility well.

And then the final line of the video,

"Remember that old way didn’t just happen by itself. It’s not like gravity that we just gotta live with. People created it. And we’re people too. So let’s create something new."

We have created the system that we currently have. Does the current system protect our world? Does it help us to be happier? I don't think so.

Even though some people may think "there is no other way" we have to remember this: we created this system, and we can create a new one. We can find a new way.

Further reading:
[1] Happiness versus consumption on No Impact Man
[2] Sustainable consumption's "double dividend" on No Impact Man
[3] Slower consumption by Dr Tim Cooper – Journal of Industrial Ecology (via No Impact Man)

Modifying controls for a BMW R1200GS motorcycle

I would like to share a bit about a small project that I did back in September. Stephan Thiel from Hex Microsystems contacted me about a friend of his who he does off road biking with. His friend, Kobus Raath, has had a below elbow amputation - that is, he has no left hand. Obviously this poses challenges when riding a motor bike, especially an off-road one!

The BMW R1200GS motorcycle

Kobus has been creative enough to overcome all the obstacles to riding so that he can really enjoy his passion. He has modified the left handle bar so that a prosthesis (which he makes himself) can attach to it, and moved the clutch to the right handle bar.

Modified left handle bar	Modified right handle bar

So the next problem he needed to address was the riders controls, such as the indicators and horn. Here are some stock photos of the right and left handle bar controls for the R1200GS from BMW (the bike Kobus rides).

Left hand controls	Right hand controls

As you can see the left indictor, horn, brights/dim, ABS and Trip function buttons are all situated on the left handle bar, making them difficult for Kobus to access while riding (and slightly dangerous too!) - and that is where I come into the picture.

The first thing that I needed to do was analyse what the constraints of the motor bike were so that that I could decide on a plan of attack.

Kobus did his research when he went about choosing which motor bike to buy. The electrical system R1200GS runs on a CAN bus and there is a controller that performs all the functions. This means that it is relatively easy to achieve the required actions by stimulating the inputs of the controller, or in other words, we can trick the controller into thinking that one of the rider controls has been pushed.

The next step was to decide on how Kobus interfaced with the system - in the end we decided to do it like this,

Sequence	Action
Right indicator: single click	Right indicator
Right indicator: double click	Left indicator
Right indicator: push and hold	Horn (until released)
Indicator cancel: single click	Brights/dim toggle

In retrospect we made a mistake by not keeping the indicator cancel as its normal function and then using a double click for the brights/dim toggle. The indicator cancel has an auto cancellation, but it only occurs after a certain distance which can sometimes cause confusion when driving in urban areas. Other than that small oversight the controls turned out to work quite well with this method.

From there on it was all implementation, construction, and debugging.

I managed to find the wiring diagrams r1200gs.info. The switch configuration is relatively simple as each switch simply pulls one of the controller inputs down to ground to activate its function. The final solution was a simple microcontroller to time the inputs from the right hand controls and to switch the controller outputs based on the depression sequence of the controls. I had some trouble with the microcontroller acting a bit erratically when the motor bike was on, but that was solved by making the code more robust to erroneous inputs.

Kobus had this to say about the final system,

"Hi Duncan,

Just a word of thanks for the construction and programming of the control unit for my bike. It makes a world of difference being able to control my electrical systems by one hand. The upgrade made all the difference and the feel of the controls is excellent.

Again, thanks for some fantastic service.
- Kobus"

Kobus taking a ride

I hope that this brief description of a simple project will give you some more insight into what I do (and can do), and how I go about approaching it. I really want the things that I create to serve their user, not the other way around.

Creating simple interfaces and building a better life for my users is the most important aspect of my designs. I hope that I'll be able to do that for you some time soon.

---

Thanks to Kobus for the photos of his bike, H Marc Lewis for providing the great website r1200gs.info and Hex Microsystems (check out their GS-911 diagnostic tool for BMW motorcycles)

The art of engineering

The advert ends with the line, "The walls between art and engineering exist only in our minds."

There are a couple of ways to interpret the catch line and it really depends on how you view art and engineering (surprise, surprise). I would say the way that the advertising company wants you to interpret that statement is that BMW have highly engineered cars with wonderful aesthetics. My interpretation? Well, maybe less obvious and possibly more true to the artist's feelings.

Let us start by looking at the word "art". Here are two definitions from Dictionary.com,

art (n) :
1. the quality, production, expression, or realm, according to aesthetic principles, of what is beautiful, appealing, or of more than ordinary significance.
2. skill in conducting any human activity: a master at the art of conversation.

So we have two (of many) definitions, one focussing on aesthetics (the "typical" association with art) and another focussing on skill at doing something. I am going to diverge a little to tell you a story about my wife and the dentist - yes maybe you think that is strange, but bear with me for a bit...

My wife really dislikes the dentist (is that applause I hear in the back row?) - until she met a lady dentist in Pretoria. Now the first thing that my wife normally tells a dentist when she sits down in the chair is how much she does not like them and how she does not understand why anyone would like to become a dentist. Luckily this tends to break the ice and lead to a good relationship :). So when the topic of, "Why would anyone want to become a dentist?" came up with this particular dentist she responded by saying that for her it was a form of art. She really took pride in how she did her work so that it would be both aesthetically pleasing and functional. Obviously it requires a skillful dentist to do this well.

So who of you would have said that a dentist was an artist? (that is, other than a torture artist ;) )

Maybe the question that needs to be asked is how far apart art and engineering actually are. In general it seems that people put them at opposite sides of the spectrum with art being all about creativity and engineering all logical and scientific. I think that what Joe Average does not realise is the degree of creativity that engineering requires and that is most likely due to engineers lack of ability to explain what we do (see my previous post on this).

For me the art of engineering is so much more than just creativity - it is something that goes to the core of function, aesthetics, and problem solving. I believe that we as engineers need to create solutions that actually enhance people's lives. The point where all of this comes together is the point were we as engineers can start to be artists.

It is more than function and more than beauty - true engineering art should take your breath away and change the way you see the world. That is the kind of art that I want to create.

I've just realised that I can't think of something off the top of my head that embodies those principals. I'm going to have to go scratch around and find some examples of what I think encompasses the art of engineering (I see a "Top Ten" post coming on). Do you have anything that you think stands out as an amazingly engineered product? Let me know by posting a comment!

A final thought - take the time to be an artist at what you do. This will enhance the lives of the people around you, and most importantly your own life, and the ripple effect of that is huge.

PS. If you're looking for a great dentist in Pretoria (or Tshwane, or whatever you want to call it), try Dr. Cornel Cronje (drop me a line if you want her contact details).
__________________

PPS. I've added a "Current Reading" section to the links on the right so that you can check out what I'm (hopefully) enjoying at the moment. The link will take you through to the Exclusive Books website (I'm an affiliate) where you can buy books and have them delivered for free to your nearest Exclusive Books.

Technorati tags : engineering, art, exclusive books