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What About The Boards?


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#31 mali

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Posted 06 January 2010 - 03:28 PM

+1

#32 Dead1nside

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Posted 06 January 2010 - 03:31 PM

I appreciate such a detailed post MWeston, trying to understand the process and what's going on is all I want.

As you say, it's a shame that the cases are what we're waiting for but lets just hope this time the 15th Jan is perfect.

I'm thankful that you're so dedicated to this and thank you for all the time you have and will put into this.

#33 calc84maniac

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Posted 06 January 2010 - 03:32 PM

So in other words you'll have the assembly process in a pipeline. :D Make sure you have branch prediction on though

#34 SONY

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Posted 06 January 2010 - 03:37 PM

All 4000 boards have not been populated yet. It actually becomes an issue with storage to have so many boards sitting built all at once. They have to be kept somewhere which tends to be awkward because boards must sit in ESD safe trays on grounded carts (remember that picture of the 80/105?). Issues with humidity control are important because parts are no longer sitting in sealed bags, although they are already soldered so it is more of a general storage thing. Craig meant that absolutely everything is ready to go, absolutely every part is sitting at the facility, things are being tested carefully and slowly still, the build process is understood...umm I don't know what else to add so I don't read the next 10 pages about how the sky is falling. :) There is merit in being vague, but I'll take the chance anyway.

Some continuing issues with alignment or fit in the test jig back in December held things up slightly. The Christmas holiday/New Year didn't help past the 24th either. The New Year has things running again and it's obvious now the PCBs are not the bottleneck. Damn plastics company. <grumble grumble>

Before any arm chair engineers pop in, please be aware that building the boards is a well understood process at this point and done very quickly. The pick and place machine can jam them out as quickly as you can keep the reels loaded. The boards are being built in batches according to how fast they can be tested. Currently that is going to stay at about 450-500 at a time. The process is to build 500, get them into testing and build the next 500 while the first ones are being tested. Once cases are available, the third parallel step will be to have a batch of 500 being assembled while a previous set is in testing and another new set is being populated.

All 4000+ antenna boards and LCD cables have been assembled and inspected. Building and testing will continue throughout January and be ready for the cases. As usual, I have to fear the backlash from misunderstanding my words and I have to read over what I type 10 times before posting it but keep in mind that most of you don't and aren't expected to truly understand this process. Things are progressing in the natural fashion a small run (by any big company's standards) like this should be done. When the cases show up, this parallel process will fall right into place and pump out shipments at a steady and predictable rate that has been expected from day one. We can't build and ship all 4000 in a day or even a week but it will be done as quickly as possible.

Some people talk about how we should spare no expense to get these done sooner and we agree. I might bring my wife to Texas to help with the labour in order to get more done sooner and I'll probably spend 12-15 hours a day on the floor building these bad boys (if they will let me) to get them to you all as fast as humanly possible. It's going to be an exhaustive and miserable process, but that's not for any paying customer to care about. :)

I have created a well documented assembly manual for the Pandora which contains several parallel processes that can be set up as stations. There are six sub stations and two main stations. The main stations (assembly of lid and assembly of base) require the most staff in order to crank them out faster. The sub stations require one person each (could be more if there are people) and are monotonous (ie. trim and solder speaker wires, apply copper tape, etc.). They could also be combined into more tasks and fewer stations. Hopefully this helps people understand that no news on the forum does not mean nothing is happening. It has never stopped being a lot of work behind the scenes.


Thanks, Michael. Awesome, post with great detail.

Much appreciated. :)

Now I don't know what I'm going to do between now and the 15th January '10.

* sits in corner of room shivering, whilst repeating the line, "the 15th couldn't come any sooner" *

#35 Bosbeetle

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Posted 06 January 2010 - 03:41 PM

Great post mweston! Really appreciate the detailed view behind the scenes.

#36 Awakening

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Posted 06 January 2010 - 03:45 PM

Thanks for the very detailed post MW, now we should all understand the process better :)

I also like the fact that you are doing proper testing of all the boards, I was a bit concerned about that.

#37 Beepo

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Posted 06 January 2010 - 04:48 PM

Ahhh that's lovely. Information is flowing now in a way that nobody can moan or grumble. THANK YOU ALL :)

<very happy boy>

#38 Xenu

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Posted 06 January 2010 - 05:13 PM

"Another two months ™" has become "another two weeks". Two weeks until the cases are ready, two weeks of shipping, two weeks of assembly... We are ceartainly getting closer and closer...

#39 DroneB Dev

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Posted 06 January 2010 - 05:18 PM

XD as long as it doesnt work as a limit.

limit t->0 {2*t} : 0<t<week<month<year;

#40 Monk

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Posted 06 January 2010 - 05:37 PM

Many thanks for your post ED, which was somewhat illuminating, but the one that followed by MW was pure gold IMHO, glarifying and adding extra detail...

umm I don't know what else to add so I don't read the next 10 pages about how the sky is falling. :) There is merit in being vague, but I'll take the chance anyway.


I think your post was, as is often the case, very informative. Full of data and apparently BS free, just like I like 'em! We'll generally have to agree to disagree on the benefits of being vague, although I understand that I am not everybody.

The boards are being built in batches according to how fast they can be tested. Currently that is going to stay at about 450-500 at a time.


etc. Excellent :)

As usual, I have to fear the backlash from misunderstanding my words and I have to read over what I type 10 times before posting it but keep in mind that most of you don't and aren't expected to truly understand this process.


I'd like to disagree about the backlash. I really would. I most strenuously wish I didn't know what you were talking about... but I also have to say that clarity like that post has to - HAS TO - have a far reduced prospect for confusion and backlash than vague comments that are open to interpretation (please - let it be so! LOL). As for understanding - I suspect a lot of people will be able to easily follow the layman's phrasing that you're using, no worries :)

I have created a well documented assembly manual for the Pandora which contains several parallel processes that can be set up as stations. There are six sub stations and two main stations. The main stations (assembly of lid and assembly of base) require the most staff in order to crank them out faster. The sub stations require one person each (could be more if there are people) and are monotonous (ie. trim and solder speaker wires, apply copper tape, etc.). They could also be combined into more tasks and fewer stations. Hopefully this helps people understand that no news on the forum does not mean nothing is happening. It has never stopped being a lot of work behind the scenes.


That's inteesting - that in itself might be a fun thing. Keep the original handy so yo can produce an after-market copy for modders and repairers, eh?

Edited by Monk, 06 January 2010 - 05:37 PM.


#41 DroneB Dev

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Posted 06 January 2010 - 05:49 PM

it would be great to have a Repair manual, every good superb gadget should have one, so no expensive fees to specialist or to break the case
to find out that you just had to push here here and there in order to open it pain less and without ripping off the video strip.

#42 calc84maniac

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Posted 06 January 2010 - 11:38 PM

XD as long as it doesnt work as a limit.

limit t->0 {2*t} : 0<t<week<month<year;

You mean it will be sitting on my front porch and there will be an endless 2 nanoseconds before I can open it? D:

#43 jonlad1

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Posted 06 January 2010 - 11:39 PM

BEST. UPDATE. EVER!

Cheers Michael, that should shut people up for a little while :lol:

#44 WizardStan

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Posted 07 January 2010 - 12:23 AM


XD as long as it doesnt work as a limit.

limit t->0 {2*t} : 0<t<week<month<year;

You mean it will be sitting on my front porch and there will be an endless 2 nanoseconds before I can open it? D:

Zeno strikes again!

#45 MDave

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Posted 07 January 2010 - 12:25 AM

Thanks MWeston, please keep us informed like that! And Craig, just keep posting emails too!

We are spoiled, truly spoiled. :P