Journey of a Hardware Startup - PowerPoint Presentation

1. Journey of a Hardware StartupPanelists:Dan Radomski, LTU Centrepolis Accelerator & FuzeHubMichael Riedlinger, NextCorpJC Jung, TARFORMSteve Hoover, RITModerator: Kim Lloyd, FuzeHub1

2. Basic Principles Observed and ReportedTechnology Concept and/or Application Formulated Proof of concept analyzed and experimented onComponent or system validation in lab envm’tSystem validation, testing in operating environmentPrototype/pilot system verification in operating environmentFull Scale prototype verified in operating envm’tActual System complete and functioning in operating envm’tActual system tested and data collected over lifetime of systemTRL 123456789Basic Tech ResearchFeasibility ResearchTech DevelopmentTech DemonstrationSystem CommissioningSystem Operation RetreatProgressProgressProgressTechnology Readiness Levels – Not Linear!

3. We got it to work…now what?The Manufacturing Scale-Up Challenge3

4. Design for Manufacturing Case Study ExampleLED Daylight EmulatorCompany Description:Daylight emulator: fake skylight with color tunable LED light that can simulate daylight (sunrise to sunset) with user-facing mobile app or linked to outdoor daylight sensorsSource: Arborlight4

5. Manufacturing Readiness Level (MRL)MRL 4Design for Manufacturability or Scale Up Challenges Faced1st generation luminaire product cost too high (BOM $5,000), traditional skylight $1,000 ($2-4K installed)Stamped optical mixing chambers with tooling was too expensive $800/each (x4 = $3,200)Product too big at 16” depth, needs to meet ASHRA industry specification standards of 8” depth Capital cost for in-house production too expensiveExperience Facing those ChallengesDesign for Packaging/Customer Use: Worked with experienced product engineering firm to redesign chamber to optimize depth of optical mixing chamber to maintain performance of color mixing while reducing mfg costDesigned for Cost: switched from stamping to extrusion process with flexible tooling to reduce costDesigned for Assembly: eliminated non value parts to reduce cost/labor, limit installation concernsSecured multiple contract assembly partners to reduce capital cost, ensure inventory & product lead timesDFX Case Study Example – LED Daylight Emulator5

6. Design for Customer Use and Market AcceptanceCustomer interface, acceptance, installationSafety, ergonomicsMarket regulations, certification requirementsDesign for Manufacturability, Assembly Reduce Bill of Material (BOM), evaluate material trade offs, cost reductionsReduce Bill of Process (BOP) or process steps, reduce laborReduce capital equipment, tooling costsReduce scrap, improve yieldDesign for Durability, Design for Operating EnvironmentConsider noise, vibration, harshness (NVH), loading conditions, temperature operating environment, engineer for lifetimeDesign for Installation & System IntegrationConsider form/fit/function, system operating dynamics, transient impacts on connecting components Design for Maintenance and ServiceabilityConsider ease of service, repairDesign for Packaging and LogisticsConsider product protection, shipping logistics, storage, transportation costs Design for SustainabilityConsider use of bio-based materials, allow for recyclability, biodegradable products and packagingReduce waste materials in operations, cradle to cradle strategy for input to waste materialsDesign for X - What are we designing for?

7. Enter Build4ScaleTMWHAT IS BUILD FOR SCALE?Build4Scale is a training curriculum designed to help developers of “hardware” physical products commercialize their innovation efficiently utilizing design for manufacturability principals. The online training program can be found at www.build4scale.org.WHO CREATED BUILD4SCALE?Build4Scale was funded by the Department of Energy and developed by Lawrence Livermore National Lab, which utilized contractors including our instructing partner, Dan Radomski, to help create the training curriculum.WHO IS BUILDD4SCALE FOR? The audience that will see the most value in this training program are new and next stage product manufacturers—companies with a new physical “hardware-based” product that, at minimum, have already developed alpha prototypes and now need to move to market with beta prototypes and transition to scale to low to medium volume.7

8. http://www.build4scale.org/Build4Scale Curriculum

9. FuzeHub and its partners from across the state were selected by the Department of Energy to deliver Build4Scale manufacturing with the following goals:Teach fundamentals to hardware innovators with attention to cleantech companiesAssist in forging partnerships with domestic manufacturers. 1on1 assistance with MEP product development and manufacturing expertsEquips hardware innovators with the training and information they need to create manufacturing-ready prototypes, avoid costly redesign, and work with manufacturers.9FuzeHub Build4Scale Program

10. 2018-2019 Build4Scale ProgramTrained over 130 innovators/stakeholders at 6 live workshops and 1 virtual workshop, across New York State (NYS)1on1 support to companies with MEP product development and manufacturing experts Contributed directly/indirectly almost $100,000 in project funding for Build4Scale projectsOver 40 connections to domestic suppliers were made after the workshop and as a result of the project funding$173,140 in domestic contract dollars generated & 10 partnerships forged between trained innovators and domestic manufacturing firmsPartnership with NYSERDA Manufacturing Corps (M-Corps) Centers10

11. Won year 2 grant to continue workOffering additional live workshops and virtual trainingPersonalized 1on1 product development and manufacturing assistance in the form of custom on-site training, being a project advisor, and matching team supportPool of additional dollars for Build4Scale manufacturing readiness projects112019-2020 Build4Scale Program

12. Do You Need Help With…12Do you have a good handle on these?Manufacturing ProcessCost of Goods SoldDo you have the following prepared?Bill of materialsBill of processEngineering drawingsAssembly drawingsDo you have the following established?Quality standardsDesign change tracking systemsDocument management systemsProduct lifecycle management systems

13. Mfg 101: Leaning Your Product Design WorkshopDesigned to accelerate the commercialization and scale up of “hardware” physical product developers. We will cover:Design for manufacturability and lean product design concepts utilizing a structured methodology for evaluating your Bill of Materials (BOM)How your product is produced/Bill of Process (BOP) and defining your potential failure modesHow to move from proof-of-concept to alpha and betaPrototypes to production scale, using tangible exercises that directly support your manufacturing needs by identifying potential manufacturability issues early on that could prohibit commercialization and long-term viability.13

14. Lean Product Design® Example

15. LEAN PRODUCT DESIGN CASE STUDYButtons2Button by WareologieRedesign Showing ChangesFinal DesignXXXXX