Hardware Design and Developement

Procedure

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HARDWARE DESIGN AND DEVELOPEMENT PROCEDURE REV: D.00

Change History
Version Date Author Description
1 7/20/06 Initial Draft
2 8/31/06 Updated Draft
3 9/12/06 Updated Draft

A 9/14/06 Release
ECO00313

B 1/19/07 Revised to include new terminology.

C 3/15/07 Updated the “Proprietary and Confidential”
statement
D 08/17/2012 Update to current processes
D.01 03/07/2013 Hart InterCivic Update to current filenaming and version
conventions

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Table of Contents
1 PURPOSE ..........................................................................................................................4
2 INFORMATIVE REFERENCES ......................................................................................4
3 FLOW CHART ...................................................................................................................4
4 HARDWARE ENGINEERING PROCESSES ...............................................................4
4.1 Functional Specifications ............................................................................................................. 4
4.1.1 Elements ................................................................................................................................ 5
4.1.2 Review and Approval ........................................................................................................... 5
4.1.3 Design Control ...................................................................................................................... 5
4.2 Preliminary Designs ...................................................................................................................... 6
4.2.1 Electrical Design & Development ....................................................................................... 6
4.2.2 Mechanical Design & Development ................................................................................... 6
4.2.3 Cross-Functional Design Review ....................................................................................... 6
4.3 Prototype Phase ............................................................................................................................ 6
4.3.1 Circuit Board Assembly and Testing ................................................................................. 7
4.3.2 Mechanical Prototypes ........................................................................................................ 7
4.3.3 Cross-Functional Review .................................................................................................... 7
4.4 Development Phase ..................................................................................................................... 7
4.4.1 Circuit Boards Assembly and Testing ............................................................................... 8
4.4.2 Mechanical Prototypes ........................................................................................................ 8
4.4.3 Cross-Functional Review .................................................................................................... 8
4.4.4 Design Control ...................................................................................................................... 8

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1 PURPOSE

The purpose of this procedure is to outline the steps necessary to design and develop
electrical and mechanical hardware for new products or major changes to existing
products. The Engineering and Management teams may determine that some of the
phases do not apply to a given project or that some of the deliverables can be pulled up
into an earlier phase. In such cases, the reasoning behind the decisions will be
documented and stored in the SharePoint Project Folder (SPF) or design history file. In
addition, the Project Plan will be modified to eliminate the unnecessary phases and to
update the deliverable milestones.

If scope changes are requested, they are negotiated, approved and documented using
the Project Scope Change Form or some other appropriate means. Records of the
project scope change are kept in the SPF in compliance with the Records Retention
Matrix.

2 INFORMATIVE REFERENCES

• ISO9001:2000 5.2 Customer focus

• ISO9001:2000 7.3 Design and development

3 FLOW CHART

Hardware Design and Development

Hardware Engineering

Product Reqs,
Inspection
Master Test Plan, Functional Preliminary Prototype Development
Reports,
Project Plan, Design Spec Designs Phase Phase
Samples
Reqs

4 HARDWARE ENGINEERING PROCESSES

4.1 Technical Reference Document and Functional Specification Package

The Technical Reference Documents (TRD) and Functional Specification Package

expand the requirements presented in the Product Requirements document with the
appropriate level of detail so that electrical circuit designs, 3D models, etc can be
designed and built.

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The deliverables include, but are not limited to:

Approved Technical Reference Documents and Functional Specification
Package
4.1.1 Elements

Elements of the Functional Specification Package that are related to Hardware are
underlined below are the following as applicable, but are not limited to:

1. Technical Reference Documents

• System throughput, maintenance and power requirements

• Security
• Ballot format
• Ballot marking parameters
• User interface
• Configurable settings
• Required outputs (i.e. Reports)
• Communication interfaces
• Error Handling
• Operational Diagnostics

2. Memory requirements
3. Mechanical requirements
4. Subsystems requirements
5. Environmental requirements
6. Agency requirements
7. Test reports

Once the Functional Specification Package is completed, it is submitted for review and
approval.

4.1.2 Review and Approval

The Functional Specification Package are distributed to Engineering and Program

Management for their review and approval. Approved changes are incorporated into the
Functional Specifications. Records of the review and approval are maintained in the
SharePoint Project Folder in compliance with the Records Retention Matrix.

4.1.3 Design Control

The approved Functional Specifications are released to Document Control following the
Engineering Change Order procedure.

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4.2 Preliminary Designs

The deliverables may include, but are not limited to:

Project Plan, which may include:
Schedule
Budget
Resources (including external to Hardware team)
Capital
Risk Matrix (Risk items with initial Mitigation Plans)
Product Allocation Plan (units for Sales, Marketing, ITA, Agency, testing, etc.)
Build quantities at each phase
Block Diagrams
Preliminary ITA involvement and planning
4.2.1 Electrical Design & Development

Electrical design consists of refining the block diagram and drawing the schematics
based on the Functional Specifications. A peer design review may be held prior to
submitting the design for cross-functional review.

4.2.2 Mechanical Design & Development

Mechanical Design consists of drawing industrial design sketches, creating the 3D

Model and the corresponding 2D drawings. A peer design review may be held prior to
submitting the design for cross-functional review.

4.2.3 Cross-Functional Design Review

After the preliminary design has been completed, a meeting is held with representatives
from Electrical Engineering, Mechanical Engineering and Program Management to
review the design and propose any necessary changes. Approved changes are
incorporated into the electrical and mechanical designs.

Records of the Preliminary Design Cross-Functional Design Review are kept in the
SharePoint Project Folder in compliance with the Records Retention Matrix.

4.3 Prototype Phase

The prototype process consists of taking a preliminary design concept and creating a
small number of prototypes and/or subassemblies to begin the test and inspection
process. Early design concepts are explored. SLAs and machined parts are allowed as
appropriate.

The deliverables may include, but are not limited to:

Updated Project Plan
Preliminary schematics
Preliminary models
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Acceptable risk level

Functional prototype subsystems or product
Update to ITA
4.3.1 Circuit Board Assembly and Testing

The board and electrical components are built internally or by a supplier. The
completed PCBA is subjected to various tests, based on test plans specified in the
Functional Specifications, which may require proving the design concept is feasible and
that the PCBA samples are functional.

Results of the evaluation and verification of the electrical prototype sample(s) are
maintained in the SharePoint Project Folder in compliance with the Records Retention
Matrix.

4.3.2 Mechanical Prototypes

Mechanical prototypes such as models, SLA, machined parts, etc. are created internally
or externally as applicable for concept visualization. Samples may be submitted to the
Contract Manufacturer to evaluate Design For Test (DFT) and Design For
Manufacturability (DFM).

Results of the evaluation and verification of the mechanical prototype sample are
maintained in the SharePoint Project Folder in compliance with the Records Retention
Matrix.

4.3.3 Cross-Functional Review

Upon completion of the tests and inspection reports, a meeting is held between the
Engineering groups and Program Management, to review information and identify
issues. Every item on the Functional Specification document may be reviewed as
necessary. Approved changes are incorporated into the electrical and mechanical
designs.

Records of the Prototype Phase Cross-Functional Design Review are kept in the
SharePoint Project Folder in compliance with the Records Retention Matrix.

4.4 Development Phase

The Development phase consists of taking the prototype design and creating a small
number of units to begin the system integration test and inspection process.

The deliverables may include, but are not limited to:

Updated Project Plan
Acceptable risk level
Mature schematics, PCB layout, BOM, models
Form Factor defined
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Functional prototypes
Update to ITA
Verification Test Plan
4.4.1 Circuit Boards Assembly and Testing

The board and electrical components are built internally or by a supplier. The
completed PCBA is subjected to various tests, based on test plans specified in the
Functional Specifications, which may require verification that all items are present, that
the electrical components fit in the housing and that the circuit boards samples are
functional.

Results of the evaluation and verification of the electrical prototype sample are
maintained in the SharePoint Project Folder in compliance with the Records Retention
Matrix.

4.4.2 Mechanical Prototypes

Mechanical prototypes such as models, SLA, machined parts, etc. are created internally
or externally as applicable for concept verification. Samples may be submitted to the
Contract Manufacturer to evaluate DFM and DFT.

Results of the evaluation and verification of the mechanical prototype sample(s) are
maintained in SharePoint Project Folder in compliance with the Records Retention
Matrix.

4.4.3 Cross-Functional Review

Upon completion of the tests and inspection report a meeting is held between the
Engineering groups and Program Management, to review information and identify
issues. Every item on the Functional Specifications document may be reviewed as
necessary. Approved changes are incorporated into the electrical and mechanical
designs accordingly.

Records of the Prototype Phase Cross-Functional Design Review are kept in the
SharePoint Project Folder in compliance with the Records Retention Matrix.

4.4.4 Design Control

The approved Functional Specifications document is released through the Document

Control procedure.

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