I’ve worked on projects at various stages of maturity, which call for different approaches depending on product-level priorities. These stages blend between one another, are often iterative, and the projects I’ve been exposed to have defined their phase segmentations differently, but here’s a generalised overview:
Conceptualisation
Proof-of-concept
Early-stage Prototypes
Late-stage Prototypes
Start-of- / Post-production
- Searching for product market fit
- Primary and secondary research to scope end-customer painpoints and needs
- Ultra-low fidelity prototyping to demonstrate design intent
- MVP: defined product category and form factor
- Gathering feedback from early adopters to verify value propositions
- Quick iterations with rapid prototyping and off-the-shelf components
- Functional testing (engineering validation tests)
- Top-down analysis: requirements and system decomposition to identify key risks
- Early manufacturing considerations for part design and assembly / install
- Process-driven change management during or after start of production
- Detailed optimisation for cost-down and long-term reliability
- Detailed function and manufacturing de-risking (design and production validation tests)
- Bottom-up tests: verification and integration
- Pre-production samples, first article inspections
Arrival ↗ is an electric vehicle manufacturer developing electric buses and delivery vans. By focusing on applying new materials, modularity and simplicity into engineering design, the mission is to deliver configuration flexibility and low cost of ownership to vehicle fleet operators.
Stage
Early-stage to Late-stage Prototypes
ResponsibilitiesMechanical Design Engineering // Project Engineering // Manufacturing & Production
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As a member within the vehicle interiors engineering team, I was responsible for the design development of sub-systems within the driver cab area for the Arrival Bus, from vehicle integration, mechanical engineering design and project management standpoints.
This involved collaboration with cross-functional stakeholders for concept generation, design development, prototype build and verification & validation activities, and liaising with tier-1 suppliers on project engineering and resolution of technical issues.
Result:
- Took 16 sub-systems from an early-stage prototype stage to a production-ready, hard-tooled stage
- Introduced BOM cost-saves with cross-platform component commonisation and manufacturing optimisations
- De-risked sub-systems through test and verification processes