How We’re Different
Investing in design and engineering early is smart. The Maestro process integrates engineering efforts into the the earliest phases. This pulls learning into the design vision early rather than allowing for surprises to be discovered in later engineering prototypes. This early spend eliminates the delays and additional POs required of repeated engineering builds to trouble shoot.
We are driven by User Experience
Our commitment to user experience provides a constant unifying direction to our engineering efforts. The vision of user experience in all of its forms; colors, materials, surface finishes, size, shape, mass, and interactive responses serves as the foundation of our highly iterative and highly cross-functional design and development process.
10:1 ratio of world class engineers in various disciplines to deliver on a customer vision established by design.
From Idea to Mass-production
Our starting point is a holistic description of the experience we expect the product to deliver to the customer. Use Cases serve as a north-star throughout the design and development process.
We determine the major scientific, technological, and engineering principles behind the experience to identify the key figures of merit. Through engineering modeling and testing of physical prototypes we begin to understand the relationships among these figures of merit and establish high-level boundary conditions for the key elements of the product system.
The boundary conditions established during the investigation of First Principles define a design space and quantitative design goals. During the Conceptual Design phase we explore multiple options for achieving these goals. Prototype testing, finite element analysis, tolerance analysis, and hand-calculations support evaluations of figures of merit.
When the team understands the performance potential of each conceptual proposal, key stakeholders can quickly down-select and focus resources on the execution of the most promising, lowest risk design. At this point we can merge engineering details with industrial design vision which minimizes risk of costly down-stream design changes.
During later stages of development we use statistical methods to optimize tooling and manufacturing processes in an effort to achieve maximum system-level performance and minimize production costs.
EVT, DVT, and PVT denote stages of development in the design of a manufactured product. Different companies define the goals and schedules around each stage differently, but in broad strokes:
EVT - Engineering Validation Test: Can we build several units that function as expected, meeting all functional requirements?
DVT - Design Validation Test: Can we build a lot of units that function as expected and look great, meeting all functional requirement and cosmetic/appearance requirements?
PVT - Production Validation Test: Can we build tons of units that that function as expected, look great, and go together quickly and easily every time, meeting all functional requirements, cosmetic/appearance requirements, with great manufacturability metrics, i.e. process capabilities, first pass yield, rolling throughput yield?
I use vague words for quantities like "several," "a lot," and "tons" deliberately. Quantities will vary from project to project, depending on complexity, scope, and resources available.
The EVT/DVT/PVT phases occur later in the design and development process, following conceptual and prototype work. Design teams will typically put great efforts into prototyping before entering the EVT phase. This gives the design and development team time to understand the product well enough to quickly identify and rectify failures that emerge as production volumes increase.