The Case of the Field Problem
Picking up someone else's design to get it into production is a common enough situation and yet there are always interesting problems to be solved. These can get particularly challenging if that previous engineer has left the company and was the only one who really knew how the product worked. In this case, not only was it a new product, it was the first product of a new range using a new processor and new communications protocol, which we were going to develop into many more variants. So it was inevitable that there would be some bugs found by the first customers. Of course the product worked fine on the bench - it was when multiple products were wired together in the field that the bug showed up. Although as a product manufacturer we specified how the field wiring was to be done, it is never that simple. Wiring is done by third parties who don't know the product design and system requirements, so what looks equivalent to them isn't necessarily acceptable in the complete system. We should have been able to provide sufficient guidance about the wiring requirements to guarantee acceptable performance, but this requires either a lot of…
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