Electronics : Project Management and Design

by Stadtmiller, D. Joseph

• ISBN13: 9780130127297
• ISBN10: 0130127299
• Edition: 2nd
• Format: Paperback
• Copyright: 2004-01-01
• Publisher: Prentice Hall

Summary

Designed to better prepare individuals for a career in electronics, this book contains critically important concepts and the preliminary tools needed for a productive first week on the job. KEY TOPICS" Its coverage of foundation strategies reviews: the operation of a company, teamwork and the role of the electronics professional, methods of project management, an engineering problem-solving process, and the practical aspects of an electronic project. Young professionals will benefit from this guide by becoming aware of--and therefore avoiding--many of the learning mistakes that often occur in the field. For electronic engineers, project engineers, electronic design engineers, chief engineers, and engineering managers with 0-5 years of experience.

Table of Contents

The Project Environment	1	(33)
The Company Structure and Overview	2	(2)
Strategic Planning	3	(1)
The Chief Executive Officer	4	(1)
Marketing and Sales	5	(4)
Marketing	6	(2)
Sales	8	(1)
Marketing and Sales Summary	9	(1)
Engineering	9	(5)
Research and Development	10	(1)
Product Support	11	(2)
Documentation Development and Control	13	(1)
Engineering Department Summary	13	(1)
Manufacturing and Operations	14	(5)
Material Control	14	(2)
Production Control	16	(1)
Manufacturing	17	(1)
Plant Management	18	(1)
Manufacturing and Operations Summary	19	(1)
Quality Assurance	19	(4)
Quality Engineering	20	(2)
Quality Assurance Summary	22	(1)
Finance	23	(5)
Accounts Receivable	23	(1)
Accounts Payable	24	(1)
Cost Accounting	25	(1)
The Controller	25	(1)
Computer Information Systems	26	(1)
Finance Department Summary	27	(1)
Industrial Relations	28	(1)
The Role of the Electronics Professional	29	(4)
Managing Electronic Development Projects	33	(20)
A History of Engineering Project Management	34	(3)
The Early 1900s	34	(1)
Pre-World War II Era	34	(1)
Post-World War II Era	35	(2)
What Is Concurrent Engineering?	37	(2)
Total Quality Management (TQM)	39	(1)
The Results of Concurrent Engineering	39	(1)
Methods of Project Management	40	(13)
The Project Manager	42	(2)
Twelve Methods for Managing Projects	44	(4)
The Team Player	48	(5)
Approval Agencies	53	(14)
An Overview of Approval Agencies	53	(2)
The National Electrical Code	55	(1)
Underwriters Laboratories, Inc.	55	(4)
UL Product Certifications	56	(2)
UL Company Certifications	58	(1)
CSA International	59	(1)
VDE and TUV	59	(1)
CE Approval	59	(3)
International Standards Organization---ISO 9000/14000	62	(5)
ISO 9000	63	(1)
ISO 14000	64	(3)
The Six Steps	67	(14)
The Six Steps of Problem Solving	68	(13)
Example 4--1	68	(3)
Example 4--2	71	(1)
Example 4--3	72	(3)
Example 4--4	75	(6)
Step One: Research and Gathering Information	81	(22)
Researching General Failure Problems	82	(1)
Researching Design Problems---What Information Is Needed?	82	(8)
Example 5--1, Compressor Tester System	84	(1)
Technical Issues	85	(1)
Market and Application Issues	86	(3)
Financial Issues	89	(1)
Researching Design Problems---Where to Gather the Data?	90	(4)
Sources for Technical Information	90	(1)
Sources for Market Information	91	(1)
Sources for Financial Information	92	(1)
Example 5--2	93	(1)
The Project Proposal---Deliverables from Step One	94	(1)
The Project Approval Process	94	(9)
Step Two: Define the Problem (Develop Design Specifications)	103	(14)
Specifications Define the Problem	103	(2)
Specification Format	105	(1)
Specification Development	105	(5)
Example 6--1	106	(4)
Software Specifications	110	(7)
Step Three: Develop a Solution Plan (Project Scheduling)	117	(26)
The Three Phases of the Project Schedule	118	(1)
Schedule Formats	118	(3)
Gantt Charts	118	(1)
PERT/CPM Charts	118	(3)
Project Management Software	121	(7)
Example 7--1	123	(5)
Bottleneck Issues	128	(2)
Example 7--2	128	(1)
Example 7--3	129	(1)
Example 7--4	129	(1)
General Procedure for Project Scheduling	130	(2)
General Project Scheduling Procedure	131	(1)
Example 7--5	132	(1)
Scheduling Step Four---The Design Phase	132	(1)
Step Four---Design Phase Deliverables	132	(1)
Scheduling Step Five---The Design Verification Phase	133	(1)
Design Verification Deliverables	134	(1)
Scheduling Step Six---Design Improvements and Project Performance Monitoring	134	(9)
Example 7--6, Tooling Changes	135	(1)
Example 7--7, Circuit Board Changes	135	(1)
Example 7--8, Software Changes	136	(1)
Design Improvement and Project Performance Phase Deliverables	136	(7)
Step Four: Execution (The Preliminary Design)	143	(40)
Divide and Conquer	143	(2)
Example 8--1	144	(1)
Preliminary Design Issues	145	(3)
Technology Selection	146	(2)
Manufacturing Cost Budget	148	(1)
Enhancing Creativity	148	(2)
Example 8--2	149	(1)
The Initial Design	150	(1)
Example 8--3	151	(1)
Design Considerations	151	(6)
Ambient Temperature	152	(1)
EMI Immunity	153	(4)
Generated EMI Levels	157	(1)
Software Circuit Simulation	157	(4)
PSpice	158	(1)
Electronics Workbench	159	(2)
Software Design	161	(3)
Breakdown of the Problem	162	(1)
Developing Flowcharts	162	(1)
Example 8--4	162	(1)
Initial Code Development	163	(1)
Simulation	163	(1)
The Mechanical and Industrial Design	164	(19)
Industrial Designers	164	(14)
Example 8--5	178	(2)
Example 8--6	180	(3)
Step Four: Execution (Component Selection)	183	(40)
Resistors	184	(4)
Example 9--1	184	(1)
Resistor Selection	185	(1)
Thick Film Networks	185	(2)
Power Resistors	187	(1)
Variable Resistors	188	(1)
Example 9--2, Wiring Potentiometers	188	(1)
Capacitors	189	(12)
Insulation Resistance	190	(1)
Equivalent Series Resistance, Dissipation Factor, and Quality Factor	190	(1)
Dielectric Absorption (DA)	191	(1)
Capacitor Types	191	(4)
Capacitor Selection	195	(2)
Back-to-Back Electrolytics	197	(1)
Feed-Through Capacitors	197	(1)
Example 9--3	197	(3)
Example 9--4	200	(1)
Variable Capacitors	200	(1)
Inductors	201	(2)
Ripple Reduction	202	(1)
Swinging Inductor	202	(1)
Current Limiting	203	(1)
Tuned or Timing Circuits	203	(1)
Air Core Inductors	203	(1)
Iron Core Inductors	203	(1)
Variable Inductors	203	(1)
Transformers	203	(3)
Example 9--5	204	(1)
Step-Down Transformers	205	(1)
Step-Up Transformers	205	(1)
Isolation Transformers	205	(1)
Impedance Matching	206	(1)
Switches and Relays	206	(2)
Relays	207	(1)
Example 9--6	208	(1)
Connectors	208	(4)
Printed Circuit Board Edge Connectors	209	(1)
Flat Cable Connectors	210	(1)
D-Type Connectors	211	(1)
Coaxial Connectors	211	(1)
Circular Connectors	212	(1)
Military Connectors	212	(1)
Zero Insertion Force Connectors	212	(1)
Selecting Active Components	212	(1)
Developing a Parts List	213	(10)
Step Four: Execution (The Design Breadboard)	223	(36)
Introduction	223	(1)
Component Procurement	224	(4)
Manufacturers' Representatives	224	(1)
Direct Sales Representatives	225	(1)
Distributors	225	(1)
Original Equipment Manufacturers (OEMs)	225	(1)
Example 10--1, OEMs	226	(1)
Requisitions and Order Quantities	227	(1)
Safety	228	(1)
Electronics Tools	229	(7)
Soldering Iron, Holder, Sponge, and Tips	229	(1)
Desoldering Tools	230	(1)
Wire Strippers	230	(1)
Wire-wrap Tools	231	(1)
Miscellaneous Small Hand Tools	232	(1)
Resistor Lead Former	232	(1)
Integrated Circuit Extraction Tools and Static Protection	233	(1)
Circuit Board Holder	233	(1)
Hand Drill and Set of Bits	234	(1)
Solderless Breadboard	234	(1)
Test Leads	235	(1)
Digital Multimeter	235	(1)
The Soldering Process	236	(3)
Solder	236	(1)
Hand Soldering	237	(2)
Desoldering	239	(1)
Breadboarding	239	(6)
Solderless Breadboard	240	(1)
Universal PCB Breadboard	240	(1)
Surface-Mount Technology	241	(1)
Wire-wrapping	242	(2)
The Nonbreadboard	244	(1)
Breadboarding Methods	245	(4)
Implementing a Circuit Schematic	246	(1)
Assembling Printed Circuit Boards	247	(1)
DIP Integrated Circuit Removal	248	(1)
Breadboard Testing	249	(1)
Operational Tests	249	(1)
Ambient Temperature Considerations	249	(1)
Electrical Noise Considerations	250	(1)
Design for Manufacturability	250	(1)
Design for Serviceability	251	(1)
Example 10--2	251	(1)
Cost Analysis	252	(7)
Step Four: Execution (Prototype Development)	259	(46)
Introduction	259	(1)
Documentation Accuracy	260	(1)
Design Master Drawings	260	(1)
Printed Circuit Board Types	260	(4)
Laminates	261	(1)
Printed Circuit Board Manufacturing Process	261	(1)
Single-sided Printed Circuit Boards	262	(1)
Double-sided Printed Circuit Boards	263	(1)
Multilayer Circuit Boards	263	(1)
Printed Circuit Board---General Design Considerations	264	(9)
Circuit Board Design Considerations	264	(3)
Example 11--1	267	(6)
Printed Circuit Board Layout---Manual	273	(5)
The Layout Drawing	274	(4)
Printed Circuit Board Layout---Computer	278	(4)
Printed Circuit Board Documentation	282	(4)
The Fabrication Drawing	282	(1)
Solder Mask	283	(2)
Silk-screening	285	(1)
Solder Paste Screen	285	(1)
Assembly Drawing	285	(1)
Parts List and Bill of Material	286	(1)
Prototype Development and Documentation	286	(3)
The Mechanical Design	286	(1)
Software	287	(1)
Example 11--2	287	(1)
Prototype Assembly	288	(1)
Prototype Testing	289	(6)
Performance Testing---Reference Conditions	289	(1)
Performance Testing---Environmental Conditions	290	(1)
Example 11--3	290	(5)
Cost Rollup	295	(10)
Step Five: Verify the Solution (Design Verification)	305	(26)
Introduction	305	(1)
Product Assurance Testing	306	(2)
Final Software Evaluation	307	(1)
Manufacturing Process Definition	308	(1)
Manufacturing Test and Calibration	309	(6)
Board Assembly and Test---Batch Processing	310	(1)
Board Assembly and Test---Manufacturing Cells	311	(1)
Test Fixture Development	311	(3)
Test and Calibration Procedures	314	(1)
Burn-In	315	(1)
Reliability	316	(1)
Accelerated Life Testing	316	(1)
Statistical Reliability Projections	316	(1)
Product Literature	316	(1)
Customer Use and Serviceability	317	(1)
Example 12--1, Brewery Field Tests	318	(1)
Manufacturing Pilot Run	318	(1)
Design Review	319	(12)
Example 12--2, Digital Thermometer Test Fixture and Procedure Development	321	(5)
Example 12--3, Accelerated Life Testing of a Digital Temperature Control	326	(5)
Step Six: Conclusion (Design Improvements and Project Performance Monitoring)	331	(18)
Introduction	331	(1)
Performance Goals	332	(3)
Specification Changes	333	(1)
Primary Design Obstacles	333	(1)
Accuracy	333	(1)
Speed	333	(1)
Power Efficiency	334	(1)
Cost Effectiveness	334	(1)
Ease of Use	334	(1)
Schedule Performance	335	(1)
Cost Goals	336	(1)
Quality Performance	337	(3)
Quality Performance in Manufacturing	337	(1)
Customer Quality Performance	338	(2)
Example 13--1, Determination of Infantile Failures	340	(1)
Sales Goals	340	(1)
Overall Economic Performance	341	(8)
Appendix A: Component Reference Information	349	(12)
Appendix B: Test Equipment	361	(28)
Appendix C: Selected Contact Information	389	(6)
Index	395