hydration-monitoring

Client Spotlight: Transforming Hydration Monitoring with an Innovative Device

Engineering ServicesIoT Software

Intake Health, a company based in the US, is changing how hydration is monitored. Recognizing that hydration is not a static metric but a dynamic process requiring continuous assessment, Intake Health has developed an innovative solution that is both effective and hassle-free. This breakthrough is particularly significant for athletes, where hydration levels directly impact performance.

The device designed by Intake Health is elegantly simple yet highly functional. Installed in urinals, it uses advanced color sensors to monitor hydration levels in real-time. This ingenious approach eliminates the need for intrusive methods, offering seamless and efficient hydration testing.

The Role of OTA Updates in Hydration Monitoring Devices

Over-the-Air (OTA) updates are crucial for interconnected devices. They enable remote firmware updates, eliminating the need for manual intervention. OTA updates address critical issues such as software bugs, enhance security, introduce new features, and extend device functionality without human intervention. This approach is particularly valuable for devices deployed across diverse and widespread locations.

Why OTA Updates Matter

In today’s competitive landscape, timely updates are crucial. OTA updates not only ensure devices remain functional but also extend their lifecycle. They enhance user experience, enable rapid iterations, and ensure compliance with evolving industry standards, keeping devices competitive and reliable.

How we Empowered Intake Health’s Vision with Firmware Updates

Srushty Global Inc. played a pivotal role in enabling Intake Health’s hydration monitoring devices by implementing OTA functionality. Collaborating on an older NRF51 platform, Srushty revamped the firmware to include:

Seamless Remote Updates: Enabled remote firmware updates for efficient device management.

Optimized Memory Partitioning: Enhanced memory utilization to support new features.

Reduced Power Consumption: Lowered power usage from 10mA to just 25μA, ensuring long-lasting device operation.

These improvements transformed the hydration monitoring device, making it more functional, scalable, and user-friendly. Intake Health’s team appreciated Srushty’s proactive approach, technical expertise, and commitment to understanding their business goals.

“I am impressed with how proactive the Srushty team is”

“The Srushty team acted as an extension of our own, proactively ensuring they had the right requirements and delivering on time. Their implementation of OTA updates and other features transformed our device’s functionality and usability,” says Michael Bender, CEO, Intake Health.

Keep Reading: Client Spotlight: How Wetflix Solutions Realized Its Vision in Water Management
6-Ways-to-achieve-a Low-power-design-srushty

6 Ways to Achieve a Low-Power Design

Engineering Services

With the advent of technological advancements, low-power design has emerged as a crucial technology for the present and future of electrical and electronic design.

Gadgets, devices, and tools require power to function. They are designed to speed up and simplify tasks through their operation. The costs associated with these devices, including their purchase price, power consumption, maintenance, and disposal, should be kept within limits or at an affordable level. That’s where low-power design plays a crucial role. Let’s delve into the specifics!

Why Do We Need a Low-Power Design?

As you know, sources of power we rely on; such as coal, oil, and gas, are becoming increasingly scarce. The prices of these fuels are rising due to their limited availability. Additionally, the pollution caused by their consumption is drastically affecting the environment. Considering the costs associated with devices, maintenance, and eco-friendly design, Low Power Design emerges as a viable solution.

Low Power Design reduces the complexity of device functionality, simplifying the overall design. As a result, devices become smaller and sleeker due to this functional simplicity. Additionally, low-power designs eliminate the need for power modules and heat ventilation systems, such as cooling fans and heat sinks, further reducing device size.

How Do We Reduce Power Consumption in Low Power Design?

For example, consider a remote device connected to the internet via wireless technology that updates data to a server, consuming 1 watt of power per hour. Over a day, this device uses 24 watts. If we have 100 devices across a monitoring network, the total power requirement is 2,400 watts per day.

With a low-power design, we can control power consumption as follows:

  • The device connects to the server wirelessly at specific time intervals and spends the majority of its time in sleep mode to conserve energy.
  • It takes the device approximately 5 to 10 seconds to wake up and connect to the server.

In this approach, the power required to send data through the wireless network is significantly higher when compared to the power used during timer-based data transfer, allowing the device to remain in sleep mode most of the time. 

By implementing this strategy, each device can reduce its power consumption by approximately 2 watts per day. Consequently, the total power requirement for all 100 devices drops to 200 watts per day. This is how low-power design works.

How Do We Achieve Low Power Design?

Low Power Design involves the implementation of various techniques and methodologies aimed at reducing both dynamic and static power consumption in electrical and electronic designs:

  1. Clock Gating: This method restricts the clock signal only to active circuit modules, thereby reducing power consumption.
  2. Power Gating: This approach restricts power flow to inactive circuit modules, further decreasing power requirements.
  3. Dynamic Voltage and Frequency Scaling (DVFS): This technique adjusts the voltage and frequency according to the workload of the circuit modules, resulting in lower power needs.
  4. Multi-Vt (Threshold Voltage) Methods: Using different threshold voltage transistors helps avoid unnecessary power leakage, conserving energy.
  5. Firmware Development: Creating algorithms with fewer hardware requirements also contributes to lower power consumptions
  6. Thermal Management: Keeping thermal effects within limits is crucial for low power requirements. For instance, using PWM (Pulse Width Modulation) technology to supply power to a load reduces both power consumption and heat generation in the circuit.

What Are the Benefits of Low Power Design?

The main advantages of low-power design include,

  • Energy Savings: This is particularly beneficial for energy-harvesting applications, such as solar, thermal, and wind energy conversion and storage.
  • Cost Reduction: Operating circuits or devices with exact power requirements significantly reduces costs, including hardware expenses.
  • Reliability: Utilizing the latest technology in integrated chips and effective firmware control leads to more reliable devices.
  • Extended Battery Life: Battery-powered devices experience longer lifespans due to slower discharge cycles.

Cumulatively, low-power design helps create electronic gadgets that are smaller, more portable, and adaptable to various environments. Additionally, the use of easily recyclable parts contributes to a more eco-friendly life. Embracing low-power design is essential for fostering sustainable practices in electrical and electronics design, ensuring that we meet the needs of today while paving the way for a more efficient and eco-friendly future.

Do you want to talk to an expert to create a low-power design? Talk to us today!

AUTHOR

Thirunavukkarasu Thoondi

Research & Development Engineer, Srushty Global Solutions

As a Senior R&D Engineer, he brings over 30 years of extensive experience in driving technological innovation and leading the development of high-performance products. Passionate about collaboration, he works closely with cross-functional teams to ensure that R&D efforts align with business goals. He excels in designing experiments, validating prototypes, and mentoring junior engineers, fostering a culture of creativity and continuous improvement. Outside of his engineering pursuits, he enjoys doing it which further fuels his drive for innovation and excellence.

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Optimizing Optical System Design

A Complete Guide to Optimizing Optical System Design Challenges and Advanced Techniques

Engineering Services

Why Optical Systems design is crucial in modern engineering?

Optical systems play a crucial role in various industries, from medical diagnostics to telecommunications and imaging technologies. As advancements in fields like photonics and optoelectronics continue to evolve, the demand for high-performance optical systems has surged. However, designing and optimizing these systems requires overcoming various challenges related to precision, material properties, size constraints, and optical aberrations.  

We can use optical simulation tools, frugal prototyping, and 3D printing to improve optical systems development, ensuring high performance while keeping costs low. Let’s explore how

What are the Complexities in Optical System Design?

Designing a high-performance optical system is a multifaceted challenge that involves several key parameters:

  • Focal Length optimization and Magnification: These are critical to determining the system’s ability to focus and magnify objects. The right balance of focal length affects the sharpness and clarity of the final image, but it must be carefully adjusted to meet the specific requirements of the system.  
  • Field of View (FOV): Optical systems often need to strike a balance between offering a wide field of view while maintaining clarity across the entire image plane. As FOV increases, distortions and aberrations can occur, particularly at the edges of the field. 
  • Optical Aberrations: Imperfections such as spherical aberration, chromatic aberration, and astigmatism can distort the image quality. Correcting these requires precise lens design and material selection. 
  • Compactness and Weight: Many modern applications require optical systems to be compact and lightweight, especially in industries like mobile devices, drones, and medical devices. However, this compactness can introduce challenges in maintaining optical precision. 

Each of these parameters must be carefully balanced to create an optimized optical system, a task that requires both advanced design tools and careful prototyping.

How to solve Design Challenges with Optical Simulation

Optical simulation software is essential for predicting how light interacts with different components within an optical system. These tools allow engineers to simulate the path of light through various lenses, prisms, and other optical elements to ensure optimal performance.

  • Ray Tracing: Simulation tools use ray tracing to model the trajectory of light as it passes through an optical system. This helps in identifying issues like reflection losses, diffraction effects, and optical aberrations. 
  • Optimizing Lens Configurations: By testing various configurations virtually, designers can adjust factors like curvature, material properties, and alignment to optimize the system. Doublet and triplet lens systems, for instance, can be simulated to reduce spherical and chromatic aberrations, providing clearer images with minimal distortion. 
  • Material Selection: The optical properties of materials, such as refractive index and dispersion, are vital for minimizing aberrations. Optical simulation tools allow engineers to test different glass types, coatings, and materials in the virtual environment before physical testing

Simulation reduces the number of design iterations needed and allows for the exploration of alternative materials and innovative designs that would be difficult or expensive to test in physical prototypes.

Frugal Prototyping: From Simulation to Real-World Testing

Once a design has been optimized through simulation, it is critical to validate its performance with physical prototypes. For this, frugal prototyping offers a cost-effective solution, allowing engineers to test the system’s real-world performance without committing to full-scale production.

  • 3D Printing and Low-Cost Materials: 3D printing enables the rapid creation of housing and mechanical parts for optical systems. By combining this with inexpensive lenses or optical elements, engineers can build prototypes to test factors such as alignment, functionality, and ergonomic design.
  • Testing Functionality: Frugal prototypes allow for immediate testing of critical parameters like optical alignment, stray light management, and the overall system’s mechanical integration. These prototypes may not represent the final materials or precision, but they help ensure that the concept works in practice. 
  • Iterative Improvement: Prototypes can be modified quickly and at minimal cost, allowing for several iterations of design before moving to higher-fidelity versions. This process helps ensure that the final product is thoroughly tested and validated, reducing the likelihood of failures in more advanced stages of production.

Frugal prototyping ensures that designs validated through simulations also perform as expected in the real world, reducing risk and saving costs during development.

5 Key Parameters in Optical System Optimization

When developing optical systems, several technical parameters must be optimized to ensure high performance:

  • Resolution: The resolution of an optical system is crucial, particularly in imaging applications. Resolution is affected by factors such as aperture size, sensor resolution, and lens quality. The ability to resolve fine details is often the benchmark for optical system performance. 
  • Throughput and Transmission Efficiency: Throughput refers to the amount of light that passes through the optical system and reaches the detector or eye. Low throughput can result in dim or unclear images, which is especially problematic in low-light conditions. Transmission efficiency can be improved with the right selection of lens coatings and materials. 
  • Depth of Field (DOF): DOF refers to the range within which objects appear sharp and in focus. Increasing the DOF is important in applications where a wide range of distances must be in focus simultaneously, but this typically requires careful adjustment of aperture and lens design. 
  • Distortion Control: In wide-angle systems or systems with a high FOV, controlling geometric distortion (e.g., barrel or pincushion distortion) is crucial for maintaining image integrity. Lens simulations help predict these distortions and allow designers to compensate for them through better configurations. 
  • Tolerancing: In high-precision optical systems, even small deviations in lens positioning, alignment, or material properties can cause significant performance issues. Optical simulation software includes tolerancing features that allow for testing of how small errors in manufacturing or assembly impact system performance.

4 Advantages of Advanced Design Techniques

By combining simulation and prototyping, modern optical system development achieves several important benefits:

  • Reduced Development Costs: With fewer physical prototypes needed thanks to advanced simulations, and the use of frugal prototyping techniques, overall development costs are significantly reduced. 
  • Faster Time-to-Market: The combination of rapid simulation iterations and quick physical prototyping allows for a faster design process, leading to quicker product deployment. 
  • Improved System Performance: Simulation tools enable highly optimized designs, ensuring better performance across a range of parameters, including clarity, resolution, and distortion control. 
  • Higher Reliability: Testing with frugal prototypes before full-scale production ensures that potential issues are caught early in the development process, increasing the reliability of the final optical system.

The Future of Optical System Design

The design of optical systems is a complex but essential process across numerous industries. By leveraging powerful optical simulation software and frugal prototyping techniques, engineers can overcome the many challenges involved in creating high-performance, compact, and reliable optical systems. These tools not only reduce the cost and time required for development but also ensure that the final product meets the highest standards of quality and performance. 

As technologies like 3D printing and advanced simulation continue to evolve, the potential for further innovation in optical system design is vast, offering new possibilities in areas such as augmented reality, autonomous vehicles, and precision imaging. 

AUTHOR

Dhanasekar R

Design Engineer, Srushty Global Solutions

Dhanasekar is a skilled design engineer specializing in CAD and 2D drafting. With expertise in technical drawing and project management, he excels at transforming concepts into detailed designs. Dhanasekar is dedicated to delivering high-quality solutions that meet project requirements and timelines, driving innovation in every endeavor.

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chefee robotics client spotlight

Client Spotlight: Chefee Robotics Breakthrough in Kitchen Automation with Robotic Chefs

Engineering ServicesProduct Development

Kitchen automation is a promising industry with immense innovation potential. That is where Chefee Robotics stands out. “We make home robotic chefs that cook thousands of dishes from scratch at the push of a button or voice command,” says Assaf Pashut, Founder, Chefee Robotics. Any seasoned engineer would know that this is not an easy task.

According to a recent report, the projected market size for the food processing industry is a staggering $3,639,780 million by 2028, with a remarkable Compound Annual Growth Rate (CAGR) of 2.4%.

With demand soaring, brace yourself for mind-blowing technological advancements in the years ahead. Automation and autonomous equipment are at the forefront, promising both technological progress and reduced production costs. Key innovations in this dynamic sector include robotic chopping machines, 3D food printers, advanced food management systems, and cutting-edge robotics.

Chefee is at the forefront of this industry with its innovative products. Chefee Robotics specializes in automation solutions for the food and hospitality industry. Their innovative robots streamline kitchen operations, improve food preparation, and enhance customer experiences. By blending AI and precise engineering, Chefee Robotics is transforming the culinary space, offering efficient, consistent, and hygienic solutions that reduce labor costs while maintaining top-quality standards.

They are proud to partner with Srushty in one of their robotic projects. “Well-developed CADs and physical prototypes with multiple moving parts saved us tons of hands-on work and allowed multiple perspectives on the problem,” says Assaf about our collaboration.

chefee robotics client review clutch srushty

Hardware product development is our passion as a team, we have done several creations in the food robotics industry. One such standout creation from our product lab is the Veggie Cutter. This groundbreaking project marked a significant leap forward in various phases of our work. As our Head of New Product Development, Sakthi Raja aptly says, “We have to understand the physics behind every small mechanism before anything else.” This statement underscores the passion and meticulous approach invested in each project.

The Veggie Cutter. Faced with a challenging scope—restricted use of multiple blades or drums for different vegetables—the goal was clear: the machine had to chop without complications. The catch? There was only a feeder; no one should manually hold the veggie, and the machine had to cut it precisely as specified by the user. This unique challenge sparked a flurry of challenges. However, the team delivered the innovation with 4 patents. 

Similarly, we have worked on many kitchen robots and this helped Chefee identify us as a partner in their innovation. 

“Extremely responsive, professional, and friendly. Will absolutely recommend and refer to other entrepreneurs and startups, whether domestic or abroad.” writes Assaf in his testimonial.

As the market continues to expand, with their expertise and innovations, Chefee is well-positioned to meet the rising demand and continue leading the charge in redefining culinary practices worldwide.

Image credits: Chefee Shark Tank

AUTHOR

Sriram Parthiban

Business Analyst, Srushty Global Solutions

Meet Sriram, a visionary business analyst in India’s dynamic contract manufacturing sector, dedicated to serving discerning clients throughout the USA. With strategic expertise and a sharp focus on optimizing supply chains, Sriram is driven to elevate India’s manufacturing prowess on the global stage. His goal is to position India not only as a leading manufacturer for the world but also as a pioneer in setting new benchmarks for quality and innovation, shaping a revolutionary industry landscape.

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outsourcing pcb

10 Reasons Why Outsourcing PCB Assembly Services Is Beneficial for You

Engineering Services

When it comes to engineering, there are a lot of complexities and customization that vary from project to project. Many enterprises look for outsourcing engineering services, mainly outsourcing PCB assembly services helps a great deal right from reducing operational costs to a whole host of things.

When should you consider outsourcing PCB assembly services?

Before going into the advantages let me list down when you should outsource PCB assembly,

  • When you don’t have an in-house facility or team for PCB assembly
  • When facing a surge in assembly needs that would require significant investment in tools and resources for a temporary project.
  • When your in-house team lacks the specialized knowledge for PCB assembly and needs to focus on other priorities, such as new product development (NPD)
  • When you require high-quality, compliant boards that must adhere to stringent quality guidelines and testing standards.

10 Benefits of outsourcing PCB assembly services:

Saving Operational Cost:

When considering outsourcing any service, the first thought that likely comes to mind is cost savings. In fact, motivation for cost savings may have driven you to decide to outsource. Research indicates that outsourcing can help you cut down labor costs by a whopping 90%.

Your PCB layout and assembly expert will have an edge over these:

  • Expertise in schematic and layout design using CAD tools.
  • Skills in Design for Manufacturing (DFM) and Design for Testability (DFT).
  • Proficiency in testing and inspection, and knowledge of compliance standards.
  • Ability to troubleshoot, ensure signal integrity, and manage thermal performance.

Diverse expertise:

Outsourcing lets you have access to skilled expertise. For instance, these companies will have highly skilled people in PCB assembly and layout. They will also have the latest tools in the market. Moreover, they also will have high-quality checks and industry standards. You can quickly tap these potentials by outsourcing PCB assembly services to these companies.

Investment cost:

PCB assembly requires investment in machinery, certifications to manufacture, etc. By outsourcing these services, you can cut down largely on these investments. Also, investing in new employees, their insurance and retention plan will not be a burden for you, if you choose to outsource. In short, you can,

  • Eliminate equipment purchase: No need to invest in expensive assembly machinery.
  • Reduce labor costs: Access to skilled technicians at lower labor costs.
  • Avoid facility costs: No need to maintain a dedicated assembly facility.
  • Avoid bulk component purchasing: Assembly providers can procure components at reduced rates due to bulk buying.

Improve time to market:

Outsourcing provides faster turnaround time. You can speed up the PCB assembly process with the outsourced company as they will have streamlined processes. This will help you accelerate your product’s journey to market. You can quickly scale up your in-house production.

Specialized resources:

By outsourcing, you can tap the potential of experts in that field. By outsourcing PCB services, you can get specialized resources like,

  • Advanced equipment for precision assembly and testing.
  • Skilled technicians with hands-on expertise in PCB assembly processes.
  • Quality Control Tools: Automated Optical Inspection (AOI), X-ray inspection, and other advanced testing equipment.
  • Established relationships with component suppliers and efficient logistics systems.
  • With expertise in lead time management and issues.

Scalability:

Whether you need a small volume or a high volume of PCBs to be made. You can easily get it done from a vendor, who can match your output requirement. You don’t need to get into the nitty-gritty of managing these scalability issues like idling equipment or maintaining labor force.

Focus on product development:

By outsourcing PCB assembly, you can concentrate on your core competencies instead of being bogged down by ancillary tasks that consume time and resources. This allows you to focus on critical areas such as research and development for new product development (NPD), ultimately accelerating your time to market.

After-market services and obsolescence management:

Your PCB vendor can become a valuable partner in addressing board failures and service requests. They will manage the necessary resources and deliver quick solutions to any failures or critical issues, ensuring seamless after-market support.

Moreover, your PCB vendor can help you with, proactive component sourcing. Regularly evaluate and source alternative components to replace obsolete parts. This ensures continuity in production and minimizing disruptions. This will be easier for the PCB vendor, as they maintain strong relationships with multiple suppliers and stay updated on market trends and component life cycles.

Increase capacity:

With outsourced PCB services, you can easily expand the capacity of the team. The PCB vendor can be your extended team. You don’t have to invest your time and money on internal machinery and manpower. You can easily increase or decrease the capacity depending on your needs without any hassle. This will help you allocate more resources to your core needs.

Compliance and risk mitigation:

With outsourcing, you don’t have to worry about compliance to standards and risk mitigation. Your PCB vendor will have expertise in,

  • Regulatory Standards: Adhering to industry regulations such as IPC, RoHS, and UL.
  • Quality Certifications: Meeting certification requirements for product safety and performance.
  • Environmental Compliance: Ensuring products meet environmental regulations like lead-free soldering.
  • Documentation: Maintaining accurate records and documentation to prove compliance.
  • Risk Identification: Proactively identifying and addressing potential risks in design and manufacturing processes.

In short, PCB assembly outsourcing provides many advantages, including cost savings, access to specialized expertise, and efficient handling of increased volumes. It allows you to focus on core activities and new product development while ensuring high-quality, compliant products. This strategic approach can enhance overall operational efficiency and accelerate time to market.

AUTHOR

Savitha Sampath

Senior Marketing Manager, Srushty Global Solutions

As a marketing professional with a wealth of experience in digital marketing, content marketing, and branding. She specialized in creating and executing successful marketing campaigns, demonstrating notable growth. Her expertise encompasses both B2B and B2C content marketing, with a strong emphasis on inbound marketing and demand generation. She has mastered the intricacies of digital marketing, from SEO and content creation to social media strategy and PPC campaigns.

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Reducing Tinnitus in Dentists: Our Journey to a Breakthrough Engineering Solution

A Breakthrough Engineering Solution to Reduce Tinnitus in Dentists

Engineering Services

Tinnitus, commonly known as “ringing in the ears,” is a condition that affects many dentists and dental assistants due to the continuous use of dental tools and drill machines. The symptoms can manifest as various sounds, including blowing, roaring, buzzing, hissing, humming, whistling, or sizzling, significantly impacting their quality of life.

Recognizing the need to address this issue, our team was approached for a project to develop a solution to prevent tinnitus among dental professionals.

The Initial Approach: Ear Muffs and Development Boards

Our initial design included earmuffs and a development board aimed at reducing noise levels produced during dental procedures and facilitating clear communication between the dentist and the assistant. While this design incorporated a filter section to lower noise levels, it proved to be inefficient.

The Breakthrough: Integrating ANC Technology

In our pursuit of improvement, we integrated ideas and inputs from an Active Noise Cancellation (ANC) solution. This innovation allowed for significantly better noise filtering when incorporated into the previous development board. The difference was substantial, resulting in a remarkable reduction in noise levels. Dentists who tested this updated product reported a significant improvement and provided positive feedback to our investors.

Designing the Next Version

We also tackled the ergonomic design of the earmuffs to ensure comfort during long dental procedures, integrating advanced materials to balance noise reduction with wearability. Each iteration of our product has brought us closer to an optimal solution, and we remain dedicated to addressing any new challenges that arise. With this breakthrough, we are now designing the next version of our product.

AUTHOR

Sai Pratheep

Senior Hardware Design Engineer, Srushty Global Solutions

A passionate and energetic electronics engineer, keen to explore and advance in the fields of electronics and communication. With experience in Wi-Fi, Bluetooth, Ethernet, smart modules, and processors, I am known for my go-getter attitude and constant smile. Driven by a thirst for knowledge, I am dedicated to my team and organization.

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Financial Benefits of Engineering Services Outsourcing

Strategic Advantages of Engineering Services Outsourcing

Engineering Services

With the potential to save over $200,000 by outsourcing, companies can reinvest these savings into core activities, innovation, and strategic initiatives, ultimately leading to a stronger market position and sustainable success.

In today’s highly competitive business environment, companies are constantly looking for ways to optimize their operations and reduce costs. One effective strategy that has gained traction is outsourcing, particularly within the engineering sector. A recent analysis reveals that outsourcing can result in substantial cost savings, which is illustrated in the graphic below:

Engineering Services Outsourcing

Cost Savings Through Outsourcing

The graphic highlights a staggering potential savings of $206,712 by outsourcing engineering services compared to maintaining an internal team. This figure is derived from national salary and employment cost averages for a team of three engineers in the United States, as reported by Indeed.com.

Breakdown of Cost Components

HR Costs (13.1%)

Human Resources management involves significant expenses related to recruitment, training, benefits administration, and compliance with labor laws. Outsourcing eliminates many of these costs by leveraging the service provider’s existing HR infrastructure.

Engineer Costs (20.5%)

Salaries and benefits for engineers constitute a major portion of the budget. Outsourcing can reduce these costs by accessing skilled engineers from regions with lower wage rates, without compromising on quality.

Manager Costs (26.2%)

Managing an in-house engineering team requires experienced managers, adding to the overall costs. Outsourcing shifts this responsibility to the service provider, who can offer managerial expertise as part of their service package.

Real Estate and Maintenance Costs (18%)

Maintaining office space and related infrastructure incurs significant expenses. Outsourcing reduces the need for physical office space and the associated maintenance costs, as much of the work can be conducted remotely

Tools Costs (22.1%)

Engineering projects often require specialized tools and software, which can be costly to purchase and maintain. Outsourcing allows companies to benefit from the service provider’s existing tools and technology, spreading these costs over multiple clients.

Comprehensive Support Under One Roof

Outsourcing helps in significant cost reduction by bringing it all under one roof. This approach saves costs and also minimizes risks and reduces project timelines. By partnering with an outsourcing provider, companies gain access to a pool of experts who bring innovative ideas and solutions to the table, enhancing the overall efficiency and effectiveness of engineering projects.

Engineering services outsourcing presents a compelling opportunity for companies to achieve significant cost savings while maintaining high standards of quality and efficiency. By understanding and leveraging the various cost components, businesses can make informed decisions that drive growth and competitiveness in the engineering space.

AUTHOR

Arun Kumar V

Senior Engineer - QA/QC, Srushty Global Solutions

Certified Six Sigma Green Belt Quality Engineer with extensive experience in CNC machining, assembly, fabrication, and special processes such as powder coating and anodizing. Proficient in IATF 16949 and ISO 9001 auditing standards, with proven expertise in establishing and maintaining Quality Management Systems (QMS).

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Implementing-the-Problem-Solving Process

How Problem-Solving Process (PSP) Can Help You Address Complex Engineering Problems

Engineering Services

Leveraging the Why-Why-Why Technique

In today’s fast-paced and competitive engineering environment, quick and effective problem-solving is essential to maintaining operational excellence, driving innovation and capturing market share.  The Problem-Solving Process (PSP) provides a structured approach to addressing complex engineering problems, from identifying and defining problems to selecting, implementing and verifying solutions. By utilizing the Why-Why-Why Technique, engineers can dig deeper into issues to uncover the root causes, leading to more robust and sustainable solutions.  This method improves the problem-solving capabilities of engineering teams, ensuring that challenges are addressed comprehensively and systematically, resulting in successful outcomes for various engineering projects. “Fix it Once, Fix it Right!”

Let’s look at it with a simple case study.

Step 1: Identify and Define the Engineering Problem

Let’s assume we have designed a new electronic device enclosure.  During testing, it was found that the device overheats, causing performance degradation and potential damage to internal components.

Problem Definition:  The specifications require the device to operate within a temperature range of 0°C to 50°C, but it overheats, currently reaching temperatures of up to 70°C under normal operation

Step 2: Analyze Possible Failure Modes in the Engineering System

Failure Modes Analysis:   Engineers analyzed the enclosure design and identified several contributing root causes that gave rise to the overheating issue:

  • The power consumption of internal components generates heat.
  • Inadequate enclosure ventilation leads to poor heat dissipation.
  • Heat sink orientations and locations are not optimum for cooling.
  • Poor thermal conductivity materials are used in the enclosure.

Using the Why-Why-Whys Technique,

Continue to ask Why until you reach the Root Cause, don’t be fooled by Symptoms!

Why is the device overheating? Because the internal temperature exceeds the safe operating range.

Why does the internal temperature exceed the safe range? Because the heat generated internally is not dissipating efficiently.

Why is heat not dissipating efficiently? Because the enclosure lacks adequate ventilation.

Why does the enclosure lack adequate ventilation? Because the design did not include sufficient vents or cooling mechanisms.

Why did the design not include sufficient cooling mechanisms? Because the initial design focused more on aesthetics, noise levels and compactness rather than thermal management.

Step 3: Generate and Analyze Potential Solutions through Creative Thinking Potential Solutions:

  • Use additional heat sinks and thermal conductive materials to enhance heat transfer and dissipation.
  • Orient the finned heat sinks to take advantage of natural convection.
  • Redesign the enclosure to include additional vents for convective cooling, for both cool air in and heated air out.
  • Add an active cooling system (e.g., small fans) to supplement natural convective cooling.
  • Optimize the power consumption of internal components to reduce heat generation.
  • And, if necessary, incorporate phase change materials, taking advantage of the thermal duty cycle and PCM’s ability to absorb, store and release heat over time.
problem-solving-wheel-new

Step 4: Solution Set Critical Parameters Optimization and Verification Testing:

Analysis led the engineering team to redesign the enclosure to include additional vents and integrate a small, efficient fan for active cooling.  They oriented the finned heat sinks to take optimum advantage of both the natural and forced air flow within the enclosure.  They also replaced some internal materials with better thermal conductors.

Sequential Validation:

Bench Fixture Testing: The new enclosure design was tested in a controlled  worst case environment to measure temperature changes and ensure the cooling system functions correctly.

Sub-System Testing: The enclosure was tested as part of a larger assembly to ensure it interacts well with other components.

Full System Testing: The complete device, with the new enclosure, was tested in real-world conditions to verify overall performance.

These tests showed a significant reduction in the operating temperatures, keeping the device well within the safe range of 0°C to 50°C.

Step 5: Implementation of Changes and Manufacturing Try Out:

Once all of the enclosure changes were successfully validated, tooling was modified, assembly fixtures updated and the new enclosure assembly was tried out in the production environment.  The production team was trained on the new assembly procedures and quality control processes were updated to ensure consistent implementation of the new design.

Step 6: The Change is Cut-In, introduced into the Field and the Performance is Monitored:

Field performance is continually monitored to confirm that the Problem is Resolved.

In Summary:

     By following the Problem-Solving Process (PSP) and leveraging the Why-Why-Why technique, we effectively identified the root cause of the overheating issue and implemented a sustainable solution. This structured approach ensured that the problem was comprehensively addressed and quickly resolved, leading to the improved performance and reliability of the electronic device.

 

 

AUTHOR

Srushty Subject Matter Experts

Henry T. Bober

Subject Matter Expert, Srushty Global Solutions

A seasoned expert in Mechanical Design Engineering with 40 years of experience at Xerox Corporation, where he specialized in Product Development and Integration, Cost-Effective Design, Project Management, Technology Development, and Product Architecture. Holding a Bachelor’s degree from West Virginia University and a Master’s degree from the University of Rochester, Henry has been instrumental in Media Handling and Feeder Technology Development, amassing 30 US and 5 European patents. Post-retirement, he founded Fast Forward Engineering, consulting for industries such as copiers, ATMs, and medical devices, with clients including Xerox, Diebold, NCR, Siemens Medical Products, Abiomed, Sycamore Hill Designs, and Impossible Objects. Henry is currently a Subject Matter Expert at Srushty Global Solutions. Residing in Fairport, NY, with his wife Leslie and their numerous pets, he enjoys Western-style horse riding, Japanese garden landscaping, woodworking, studying naval warfare history, and advocating for animal welfare.

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Industrial Design vs. Product Design: How Each Shapes the Final Product

Engineering Services

Industrial Design vs Product Design :

In the world of design, the terms “industrial design” and “product design” often get used interchangeably, blurring their distinctions. However, a closer examination reveals nuanced differences that can significantly impact how we perceive and execute the design processes.

What is Industrial Design?

Industrial design involves the aesthetic and functional aspects of mass-produced items. Industrial design is a bit broader. It covers the design of anything and everything that can be mass-produced. This could be products, packaging, furniture, or vehicles. It’s a balance of art & feasibility, aiming to enhance the user experience as well as the product’s market appeal. It is one of the crucial steps in hardware product development.

Industrial designers craft the appearance, ergonomics, and usability of objects, prioritizing seamless integration into users’ lives.

Industrial design is focused on optimizing manufacturing processes, using effective materials and reducing cost. Born in the era of industrial revolution it now spans various industries, from consumer electronics to furniture, automobiles to household appliances. 

We are proud to be recognized by DesignRush as a top industrial design company, reflecting our commitment to innovation and excellence in this field.

What is Product Design?

Product design is a branch of Industrial design. Product design focuses on both physical and digital products and its experiences. It involves understanding user behaviors, market dynamics, and social trends to create products that resonate on a deeper level. Product designers often collaborate with multidisciplinary teams, including engineers, marketers, and psychologists, to realize comprehensive design visions.

Same, same but different?

Industrial designers infuse products with aesthetic appeal and ergonomic efficiency, while product designers infuse them with narrative coherence and emotional value.

Both disciplines are increasingly influenced by technological advancements and sustainability. From 3D printing and IoT integration to eco-friendly materials and circular design principles, designers are embracing innovation to address evolving social needs and environmental concerns.

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Still confused?

Industrial design encompasses a variety of design streams such as visual design, product design, automotive design, and space and environmental design. When you choose to focus on a specific stream like product design, you become a product designer. This can involve creating tangible or digital products, and UI/UX design is a subset of this field.

The rise of the IT sector and corporate usage of the term “product designer” for UI/UX roles has led to the misconception that product design is limited to UI/UX. However, all industrial designers understand the product design process, but only product designers specialize deeply in it.

Let’s end this war:

In conclusion, both industrial design and product design offer rich insights into the multifaceted nature of the creative endeavor. While each discipline brings its unique perspective and methodologies to the table, their convergence herald’s boundless opportunities for synergy and growth.

As designers, let’s embrace this diversity, transcending boundaries to solve problems that inspire and enrich human experience. Whether we’re sculpting tangible toys or orchestrating intangible interactions, let’s make a design with purpose, passion and empathy. After all, design is design and it can evolve in many forms in future as well.

AUTHOR

Shibi Kabilan

Lead Industrial Designer, Srushty Global Solutions

A seasoned Lead Industrial Designer with extensive experience in creating innovative, user-centered products, committed to blending functionality, aesthetics, and sustainability in design. By collaborating with engineers and other stakeholders, I bridge the gap between design vision and manufacturability.

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Exploring LoRa Technology

LoRa Technology: Solving Connectivity Challenges to Create Smart Solutions

Engineering Services

Picture a world where connectivity knows no limits, where data flows effortlessly across vast distances, free from the constraints of traditional wireless technologies. That’s the promise of LoRa – a game-changing innovation in wireless communication that’s reshaping the landscape of IoT solutions.

Practical challenges with LoRa:

We wanted to build an effective device that taps LoRa’s data-transferring ability, and with this ambitious goal we started the project. Inspired by its potential to enable seamless data transfer across distances of up to 5 kilometres without relying on traditional Wi-Fi infrastructure, we set out to turn theory into reality.

However, as with any pioneering venture, we encountered challenges. Initial tests didn’t quite meet our expectations, revealing that achieving optimal performance required more than simply plugging in sensors and hoping for the best. It demanded thorough analysis, hardware adjustments, and countless iterations to fine-tune our setup.

We cracked the LoRa connectivity:

One crucial insight emerged from our efforts – the importance of antenna height. Just like traditional network infrastructure relies on towering structures to transmit signals effectively, LoRa’s performance hinges on the elevation of signal stations. Armed with this knowledge, we optimized our setups by raising antennas to new heights, significantly improving performance.

What we are building with LoRa :

We’re in the process of developing a water monitoring system using LoRa technology. Ten LoRa-connected devices will transmit data to a central device linked to the network, providing real-time data updates. Small data from these devices can be integrated to get maximum impact cost-effectively.

Use cases of LoRa in IoT:

We see LoRa as more than just a wireless connection – it represents an opportunity to develop cost-effective, scalable solutions with wide-ranging impacts. For example, in some government organisations across countries, LoRa is used for monitoring dustbins across different locations in a 5km range. It is also used for tracking water levels. LoRa’s versatility opened doors to innovative solutions that were once thought impractical.

Breaking the Challenges in Implementing Seamless Data Transfer with LoRa:

Urban environments presented new obstacles, with mobile towers and competing frequencies posing threats to data integrity. We tested it in multiple locations in urban areas but we couldn’t achieve even half a kilometre. When we tested it in an open space, it worked! We realised the impact of these competing frequencies. Antenna placement also plays a crucial role. We devised strategies to overcome these hurdles, leveraging strategic antenna placement to ensure seamless data transmission even in urban interference.

Advantages of LoRa:

LoRa, unlocks a world of possibilities – 

  • It is affordable, we can create ridiculously cheap monitoring systems with Lora 
  • You do not need a LAN or mobile network. LoRA is a free band.
  • It is a resilient communication network, capable of withstanding natural disasters and network outages.

In a world increasingly reliant on connectivity, LoRa is reshaping the future of wireless communication. With its long-range capabilities and cost-effective solutions, it’s not just a technology – it’s a game-changer.

AUTHOR

Abinaya Selvam

Firmware Design Engineer, Srushty Global Solutions

Aspiring firmware engineer with thrust deep knowledge in field of electric design development oriented towards research, i emcompass on using advanced and reliable tech for meeting client demands. Always supportive and encouraging lightning performance in all the actions performed.  

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