Section outline

  • Planning for Scaling and Small Batch Production

    After building and testing your prototype, the next essential step is preparing to scale your project. Whether you want to make 10 units or 100, moving from a single prototype to a small batch production requires careful planning, design revisions, cost estimation, and resource management.

    • 🔧 Design for Manufacturing (DFM)

      • Redesign the prototype with fewer parts and simpler connections.
      • Choose components that are easier to source and assemble in larger quantities.
      • Replace expensive or fragile components with cost-effective and robust alternatives.
      • Ensure the design is easy to assemble even by someone with basic skills.

      📦 Bill of Materials (BOM) Optimization

      Create a detailed spreadsheet listing all parts needed for each unit and total batch. Analyze:

      • Unit cost vs. bulk cost (e.g., buying 10 vs. 50 items)
      • Reliable vendors and delivery times
      • Opportunities to use interchangeable or alternative parts

       

      Component Unit Cost Qty Needed Supplier Alternatives
      Arduino Nano $4.50 10 Online Bulk Dealer ESP32 (if Wi-Fi needed)
      Servo SG90 $1.80 10 Local Electronics Metal Gear Servo
      RTC DS3231 $1.20 10 Banggood DS1307 (less accurate)
      Custom PCB $1.00 10 JLCPCB Breadboard (not scalable)
      Enclosure $2.50 10 Local 3D Print Hub Laser-cut Acrylic

      🛠️ Batch Assembly Planning

      • Decide how many units to build in the first batch (start with 5–10).
      • Test whether the assembly process is repeatable and efficient.
      • Prepare any tools, jigs, or fixtures that reduce manual labor.
      • Plan layout for wiring, labeling, and enclosure fitting.

      ✅ Testing and Quality Control (QC)

      Each unit should undergo basic checks before being considered ready:

      • Power on and functional tests (LEDs, sound, buttons)
      • Sensor accuracy and calibration
      • Alarm and timer behavior (especially for reminder bots)
      • Durability of parts and casing

      Create a checklist to mark passed/failed items for each device. Keep logs for improvements.

      📊 Cost and Time Estimation

      • Calculate the total time to assemble one unit and multiply for batch.
      • Estimate labor cost if you have team members or external help.
      • Add packaging cost, storage logistics, and shipping options.

      👨‍🔬 Real-User Feedback and Iteration

      Before a full rollout or pitching, test a few units in real-world scenarios:

      • Deploy with 2–3 elderly users (or your target audience)
      • Ask for feedback on usability, alerts, and instructions
      • Use feedback to fix usability flaws and identify design improvements

      🎯 Final Goal of This Section

      By the end of this phase, learners should be able to build 5–10 functional units of their robot, have a clear estimate of costs and time, understand the challenges of scaling, and be prepared for documentation and pitching their solution effectively.