Hardware - Ramping Up

Shipping hardware is oh so different. Yes it does matter if you want to distribute 1k or 100k "copies". Because unlike software / apps nowadays, adding bandwidth just is not so simple.

We have products with radio modules. We have designed the module and our CM (Contract Manufacturer) is making them. They have to main parts inside: a radio protocol processor and a frontend. The latter is a combined PA (Power Amplifier) and LNA (Low Noise Amplifier). Both are used to extend the radio range. The PA boosts output, the LNA improves sensitivity.

Unfortunately there are precise regulations setting limits on the maximum transmit power level. Unfortunately each frontend chip is different. They differ in input impedance, which translates to the signal level to be amplified. So in some units the amplified signal is less than the allowed maximum, and in some it exceeds the allowed level. To maximize the performance, we have to calibrate each unit (measure the output level and software - tune it up or down a little).

The calibration process takes time and the equipment is expensive. We could multiply the test rigs. But this would cost us a lot, with the improvement being just linear. Or we could design a dedicated calibration equipment (currently we use universal off-the-shelf spectrum analyzers). Of course the second approach scales much better, but requires yet another R&D / time / material investment.

It is like building a faster Internet to allow customers download more apps you publish to an App Store. Software guys don't even have to think of such problems. Both Apple and Google have infinite bandwidth. Unfortunately our current assembly lines do not have infinite bandwidth.

While this is an unexpected problem, it is a great one to have. It simply means the products are getting traction and we, as the organization, move yet another level up. Gaining more experience and more IP in our portfolio, to empower our customers even better.