As the complexity of the circuit diagram structure of assemblies increases, prototyping becomes ever more complex. It is almost like chasing a rabbit when OEMs push for a quick market launch for new product developments, but do not show the appreciation for reliable prototyping that it actually deserves. In the end, a constantly recurring phenomenon remains: the lack of foresight with almost all costs and times for the future marketable design. More test loops, higher investments and even more bitter: a later market entry for the product inevitably looms. Development companies sometimes find it difficult to have the right Electronic Manufacturing Service (EMS) at their side to proactively incorporate their customers' time-to-market goals into the prototyping process.

Prototype construction: an optimally focused approach to series production

The German company Lacroix Electronics, a plant of the French EMS manufacturer, shows how things should be done differently and how prototyping can be made more efficient. "In our experience, it is essential to convince the customer not to order the quick prototyping interim number," says Peter Sommer, Head of Marketing and Sales at Lacroix Electronics in Willich in the Lower Rhine region. "A fully developed prototype already represents the actual product in its initial phase." All it takes is the discipline to tackle a well-versed briefing right at the start in order to include all known requirements at the time, including those relating to the procurement of components, series production and testing requirements, Sommer continues: "Proceeding in this way saves valuable time. A potential competitive advantage, especially when it comes to highly innovative product developments.

However, according to the electrical and electronics engineer, it is more difficult for OEMs to find a company among the variety of EMS manufacturers that understands how to produce production-ready layouts - for efficient, reliable and error-free series production.

When choosing an EMS, he advises product developers and purchasers to take the different production approaches of prototyping manufacturers into account: Due to their core business, EMS series manufacturers are generally good at volume production with their machinery, with complex structures for a reliable manufacturing process. As a result, however, they lack the right organization for application-intensive prototype construction. EMS service providers that focus purely on prototype construction, on the other hand, have a well-adapted machine park geared towards one-off production and designed for suitable line-in processes. What they lack, however, are the series systems - and therefore the experience for this form of production. The clear focus on one-off production also results in a different, usually more extensive time and cost structure.

Prototyping on series systems

According to Michael Hendrix, head of the newly installed three-person prototyping team, the German company Lacroix Electronics is taking a different approach for its customers. "In comparison, we see mature prototyping for the first model on series systems as a kind of silver bullet. Our principle is to present a production-ready layout as quickly as possible, for a cost-effective, error-free and reliable product," postulates the 47-year-old Hendrix, "with every redesign phase saved in this way, customers achieve a time saving of at least three months. Potentially a valuable advantage for entering the market with a decisive head start." Rainer Schoppe