A product lifecycle is the timeline of a product’s progression from conception to obsolescence. Effective lifecycle management processes ensure product quality, safety, and reliability while maintaining operational efficiency and enabling quick launch. Success requires seamless collaboration between teams and coordinating resources to plan, execute, and test products.
Companies that take into consideration product lifecycle are better equipped to design and produce higher-quality products with longer life spans. In the context of developing electronic devices, manufacturers can integrate derating practices into their approach to ensure they deliver dependable and durable products.
At Advanced Conversion Technology (ACT), we take product lifecycle seriously, focusing on addressing risks, like obsolescence and derating, early in the lifecycle to reduce the chance of failures later on. We’ve invested in the best equipment, processes, and training to ensure we design and manufacture military-grade power supplies that meet the highest quality and safety standards.
Additionally, our vertically integrated, USA-based facility enables streamlined collaboration between product developers, engineers, and production teams—enabling tight quality control and reliable timelines. Our Quality Management System (QMS) is AS9100 certified, assuring we embrace risk-based, customer-focused thinking in every lifecycle stage.
From conception to launch, companies need to verify that every stage of the product lifecycle focuses on achieving the highest quality possible while meeting customer specifications and timelines. That said, product lifecycle stages vary depending on a company’s particular approach, customer requirements, and regulatory standards. The next several sections go over these various stages.
Product development begins by understanding the customer’s requirements and preferences as well as industry standards.
For example, as a company specializing in designing and producing custom power supply solutions for the defense industry, we begin product development by asking customers questions to understand their application’s requirements. Based on their needs and specifications such as voltage, form factor, and mounting requirements, our team will verify through test, analysis, or inspection to ensure our design will comply with their specifications. We’ll also identify relevant safety criteria to guide our design and adhere to applicable military standards.
If a commercial off-the-shelf (COTS) or modified off-the-shelf (MOTS) power supply makes the most sense for our partner, we’ll recommend one of those options.
During the design stage, engineers translate customer’s specifications into an actionable plan. Using design simulation and modeling tools, they can identify risks early and optimize the design before creating a prototype.
In designing electronic devices, it’s essential to integrate derating principles to increase product reliability, particularly if the device will be used in harsh environments or demanding applications. With derating, the product development team intentionally selects materials and components that are resilient against stressors that can lead to product failure, such as voltage or heat. They’ll recommend operating guidelines below the product’s maximum capacity and validate these specifications through testing. This two-part strategy decreases the potential for failure and increases product longevity.
After designing the product, the development team will create a prototype and conduct a variety of tests to ensure the product meets safety standards and application specifications as well as validating voltage, current, output power, and efficiency characteristics.
As with the design stage, derating plays a critical role in testing and validating the prototype. For example, the testing team might test the prototype in simulated real-world conditions and measure its performance against derated specifications. If the tests reveal risks or flaws in the design, engineers can make modifications, create an improved prototype, and test it again — continuing this process until the product meets the highest quality standards.
At ACT, our cutting-edge simulation tools and manufacturing capabilities enable us to offer rapid prototyping, while our internal Environmental Stress Screening (ESS) and Electromagnetic Interference (EMI) capabilities allow us to detect issues and improve designs quickly.
A design is ready for production after internal teams, like engineering, manufacturing, and quality, review production documentation and verify that it meets customer needs and regulatory requirements. During this time, appropriate manufacturing and assembly processes are selected, considering the product materials, form factor, and design requirements.
The production team follows standard operating procedures and are highly skilled in PCB fabrication, component placement, soldering, and any other required processes.
Products will also undergo in-line testing and inspection to ensure quality as they are being built.
At our facility, all of our workmanship complies with MIL-HDBK-454 and J-STD-001 standards at a minimum, confirming that our products are manufactured to perform reliably in the most demanding applications.
After the product is manufactured and assembled, the product team must perform a final inspection and testing phase before it reaches the customer. Testing is a critical part of this step for electronic devices like power supply units. At ACT, our products are 100% tested, assuring compliance with the electrical specifications.
The product lifecycle doesn’t end after it leaves the production line. Beyond the initial release or deployment, products or systems may need things such as routine maintenance, updates, repairs, technical assistance, and part replacements. At ACT, we provide ongoing support as well, ensuring customers are satisfied with their product and have the documentation they need to operate and maintain their device safely, compliantly, and optimally.
Although military-grade power supplies are designed to meet the demands of military applications, extended lifecycle support can prolong their usability and maximize the customer’s return on investment, especially on products that need to work for an extended duration. Supporting products throughout their lifecycle helps mitigate risks associated with obsolescence and ensures extended lifecycle.
Lastly, it’s worth mentioning configuration management. Configuration management isn’t just a lifecycle stage — rather, it’s an approach to every phase of product development. It is crucial in mitigating risks associated with delays within the supply chain of power components by ensuring all components are properly documented, controlled, and maintained. It mitigates risks associated with configuration drift, unauthorized changes, and inconsistencies that could lead to system failures or security vulnerabilities.
By implementing robust configuration management practices, engineers can:
At ACT, we understand the importance of implementing robust product lifecycle strategies to develop and validate power supplies. With over 40 years of experience in designing and manufacturing highly reliable power conversion solutions, we have the expertise and state-of-the-art facilities to ensure our products meet the most demanding power requirements.
Derating and risk avoidance are critical parts of our company’s product lifecycle process, and our power supplies undergo rigorous testing at different stages of development to ensure we provide the reliable products you need to see long-term performance.
Contact us today for military-grade power supply solutions.