benikigai/ec-1Public
EC-1 Wireless Controller
SHA-256 5d27679c70a006078f617455a4be4ff71069ba4fa5df0c5e51c7e02547cd6d23
# SYNTHETIC EXAMPLE. EC-1 and Example Devices are fictional; every value is made up to show
# what an OPD holds. The card says so (card.synthetic: true). Built by tools/make_example_data.py.
# This one file is the whole product and its line, in a form an agent can read.
opd_version: 0.4.0
extensions:
- id: battery
version: 0.1.0
- id: controller
version: 0.1.0
card:
product: EC-1 Wireless Controller
maker: Example Devices (fictional)
maker_endorsed: false
synthetic: true
category:
- game-controller
- consumer-electronics
- battery-powered
- wireless
revision_examined: EC-1 rev B, SKU EC1-BLK (fictional)
units_examined: 30
license: CC-BY-4.0
base_opd: null
base_relation: null
trust_level: draft
visibility: public
metrics:
observed_share:
value: 0.367
badge: self-reported
bom_coverage_by_cost:
value: 0.966
badge: self-reported
station_evidence_share:
value: 0.455
badge: self-reported
card_completeness:
value: 1.0
badge: self-reported
rebuild_check:
value: true
badge: self-reported
reproduction_agreement:
value: null
badge: self-reported
sources:
- id: src:ct-run-1
kind: ct
ref: raw/scan-logs/ct-run-1.yaml
sha256: 144c9053a55bb8ede5b8961799d86d9eca291bc2d3be66a4b073386765d3f413
- id: src:teardown-log
kind: teardown
ref: raw/teardown-log.csv
sha256: d7c953e05077eaef3e2679cebd98b51241bed87ca330c08d38b883ba7dbca9d4
- id: src:caliper-run-1
kind: caliper
ref: raw/measurements.csv
sha256: 4e485578c0e79cf7911b550abc8fac035d7e0ce53794b10bef0166950f5e2cdd
- id: src:cmm-run-1
kind: cmm
ref: raw/measurements.csv
sha256: 4e485578c0e79cf7911b550abc8fac035d7e0ce53794b10bef0166950f5e2cdd
- id: src:xrf-shells
kind: xrf
ref: raw/xrf-shells.csv
sha256: aefe247c1ef4cfe030e8d4359d6f2b8700d0cbf34b45c4a026c8201b339c9d94
- id: src:markings
kind: marking
ref: raw/markings.csv
sha256: 46ed21205a7f44d2440bfeffecd70d58fb750a24d4afabb3a72c0efe0e5e07b6
- id: src:photos
kind: photo
ref: media/renders/
- id: src:fcc-filing
kind: filing
ref: compliance/marks.yaml
sha256: da0069bb050752c8c7d64a06ed67e3e814609dc9061a3a6531da3f76e2486390
- id: src:repair-guide
kind: repair_guide
ref: public repair guides for EC-1 stick replacement (fictional)
- id: src:reviews
kind: review
ref: raw/review-sample.csv
sha256: 6d758ebf78e695d235eb7fb9e6832fd184626169cefe97b0d3da73b83bf5a20f
- id: src:eol-sample
kind: teardown
ref: raw/eol-sample.csv
sha256: 7192c8a9896aab318b77c2832406f813735e52f7b6effa076d9fce542db5fd9c
parts:
- id: part:top-shell
name: Top shell
material:
value: PC/ABS, charcoal, light texture
source: measured
confidence: high
evidence:
- src:xrf-shells
- src:markings
note: XRF matches PC/ABS; >PC+ABS< moulded inside
process:
value: injection-moulded, 2-cavity tool
source: observed
confidence: high
evidence:
- src:teardown-log
- src:photos
note: two gate vestiges and cavity number 1 or 2 on the inside
mass_g:
value: 16.6
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units; CAD volume times nominal density gives 16.94 g
geometry:
step: parts/top-shell.step
usd_prim: /Product/TopShell
fidelity: reduced
features:
- id: feat:top-length
name: Overall length
spread:
mean: 119.9177
sd: 0.0294
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
- id: feat:top-width
name: Overall width
spread:
mean: 55.951
sd: 0.0263
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
- id: feat:stick-hole-dia
name: Stick hole diameter
spread:
mean: 21.0189
sd: 0.0154
n: 30
unit: mm
instrument_resolution: 0.001
evidence:
- src:cmm-run-1
- id: feat:button-hole-dia
name: Face button hole diameter (A)
spread:
mean: 8.213
sd: 0.0134
n: 30
unit: mm
instrument_resolution: 0.001
evidence:
- src:cmm-run-1
- id: feat:shoulder-gap
name: Gap at shoulder buttons, closed unit
spread:
mean: 0.2147
sd: 0.0493
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
- id: feat:boss-pilot-dia
name: Screw boss pilot diameter
spread:
mean: 1.7102
sd: 0.0109
n: 30
unit: mm
instrument_resolution: 0.001
evidence:
- src:cmm-run-1
markings:
- value: '>PC+ABS<'
source: observed
confidence: high
evidence:
- src:markings
- value: cavity 1 or 2
source: observed
confidence: high
evidence:
- src:markings
- id: part:bottom-shell
name: Bottom shell
material:
value: PC/ABS, charcoal
source: measured
confidence: high
evidence:
- src:xrf-shells
- src:markings
process:
value: injection-moulded, 2-cavity tool
source: observed
confidence: high
evidence:
- src:teardown-log
mass_g:
value: 18.1
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units; CAD volume times nominal density gives 18.06 g
geometry:
step: parts/bottom-shell.step
usd_prim: /Product/BottomShell
fidelity: reduced
features:
- id: feat:lip-height
name: Wall height at parting line
spread:
mean: 12.014
sd: 0.0305
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
- id: feat:parting-gap
name: Parting-line gap, closed unit
spread:
mean: 0.0993
sd: 0.0289
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
markings:
- value: '>PC+ABS<'
source: observed
confidence: high
evidence:
- src:markings
- id: part:button-cap
name: Face button cap
material:
value: ABS, off-white, pad-printed legend
source: observed
confidence: medium
evidence:
- src:teardown-log
note: legend wears on high-use units
process:
value: injection-moulded, 8-cavity family tool
source: inferred
confidence: medium
evidence:
- src:teardown-log
mass_g:
value: 0.36
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units; CAD volume times nominal density gives 0.34 g
geometry:
step: parts/button-cap.step
usd_prim: /Product/ButtonCap_1
fidelity: reduced
features:
- id: feat:cap-od
name: Cap outside diameter
spread:
mean: 7.5777
sd: 0.0097
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
- id: part:shoulder-button
name: Shoulder button
material:
value: PC, charcoal
source: inferred
confidence: medium
evidence:
- src:teardown-log
process:
value: injection-moulded
source: observed
confidence: high
evidence:
- src:teardown-log
mass_g:
value: 0.76
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units; CAD volume times nominal density gives 0.75 g
geometry:
step: parts/shoulder-button.step
usd_prim: /Product/ShoulderButton_L
fidelity: reduced
- id: part:dome-sheet
name: Silicone dome sheet
material:
value: silicone rubber, 50 Shore A
source: inferred
confidence: medium
evidence:
- src:teardown-log
process:
value: compression-moulded
source: inferred
confidence: medium
mass_g:
value: 0.66
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units; CAD volume times nominal density gives 0.64 g
geometry:
step: parts/dome-sheet.step
usd_prim: /Product/DomeSheet
fidelity: reduced
- id: part:stick-module
name: Analog stick module
material:
value: 'mixed: POM shaft, ABS cap, carbon-track potentiometers'
source: observed
confidence: high
evidence:
- src:teardown-log
- src:ct-run-1
process:
value: purchased-assembly
source: inferred
confidence: high
mass_g:
value: 6.4
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
geometry:
step: parts/stick-module.step
usd_prim: /Product/StickModule
fidelity: envelope
features:
- id: feat:stick-centre-offset
name: Stick centre offset at rest, uncalibrated
spread:
mean: 1.7033
sd: 1.0347
n: 30
unit: '% of full scale'
instrument_resolution: 0.1
evidence:
- src:eol-sample
markings:
- value: EXS-10K (fictional)
source: observed
confidence: high
evidence:
- src:markings
- id: part:main-pcba
name: Main PCBA
material:
value: FR-4, 4 layers, 1.0 mm, ENIG
source: observed
confidence: high
evidence:
- src:ct-run-1
- src:teardown-log
note: layer count from CT; finish from colour
process:
value: smt-assembled, both sides reflowed at the EMS
source: observed
confidence: high
evidence:
- src:teardown-log
mass_g:
value: 9.6
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
geometry:
step: parts/main-pcba.step
usd_prim: /Product/MainPCBA
fidelity: envelope
features:
- id: feat:board-thickness
name: Board thickness
spread:
mean: 1.006
sd: 0.0159
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
- id: part:battery
name: Li-ion pouch cell, 600 mAh
material:
value: lithium-ion polymer
source: observed
confidence: high
evidence:
- src:markings
note: read from the cell label
process:
value: purchased-assembly with protection board
source: observed
confidence: high
evidence:
- src:teardown-log
mass_g:
value: 12.4
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
geometry:
step: parts/battery.step
usd_prim: /Product/Battery
fidelity: envelope
features:
- id: feat:cell-thickness
name: Cell thickness at 50% charge
spread:
mean: 5.9163
sd: 0.0576
n: 30
unit: mm
instrument_resolution: 0.01
evidence:
- src:caliper-run-1
markings:
- value: 3.7 V 600 mAh 2.22 Wh
source: observed
confidence: high
evidence:
- src:markings
- id: part:haptic-lra
name: Haptic LRA, 10 mm
material:
value: mixed
source: observed
confidence: high
evidence:
- src:teardown-log
process:
value: purchased-assembly
source: inferred
confidence: high
mass_g:
value: 1.6
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
geometry:
step: parts/haptic-lra.step
usd_prim: /Product/HapticLRA
fidelity: envelope
- id: part:screw-m2x6
name: Screw, M2 x 6, pan head, self-tapping for plastic
material:
value: steel, black zinc
source: observed
confidence: high
evidence:
- src:teardown-log
process:
value: cold-headed, thread-rolled
source: inferred
confidence: high
mass_g:
value: 0.24
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units; CAD volume times nominal density gives 0.25 g
geometry:
step: parts/screw-m2x6.step
usd_prim: /Product/Screw_1
fidelity: reduced
- id: part:light-pipe
name: LED light pipe
material:
value: PC, clear
source: observed
confidence: high
evidence:
- src:teardown-log
process:
value: injection-moulded
source: inferred
confidence: medium
mass_g:
value: 0.05
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units; CAD volume times nominal density gives 0.03 g
geometry:
step: parts/light-pipe.step
usd_prim: /Product/LightPipe
fidelity: reduced
- id: part:rating-label
name: Rating label
material:
value: PET film, printed
source: observed
confidence: medium
evidence:
- src:teardown-log
process:
value: die-cut, purchased
source: inferred
confidence: high
mass_g:
value: 0.05
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
geometry:
step: parts/rating-label.step
usd_prim: /Product/RatingLabel
fidelity: reduced
- id: part:soc
name: Bluetooth LE SoC, 7 x 7 mm QFN
material:
value: silicon die in QFN-48
source: observed
confidence: high
evidence:
- src:markings
process:
value: purchased-component
source: inferred
confidence: high
markings:
- value: EXAMPLE BLE52 (fictional part number)
source: observed
confidence: high
evidence:
- src:markings
- id: part:imu
name: 6-axis IMU, 3 x 3 mm LGA
material:
value: MEMS in LGA-14
source: observed
confidence: high
evidence:
- src:markings
process:
value: purchased-component
source: inferred
confidence: high
- id: part:pmic
name: Charger and power IC, 4 x 4 mm QFN
material:
value: silicon die in QFN-24
source: observed
confidence: high
evidence:
- src:markings
process:
value: purchased-component
source: inferred
confidence: high
- id: part:usb-c
name: USB-C receptacle, mid-mount
material:
value: LCP body, gold-plated contacts
source: observed
confidence: medium
evidence:
- src:teardown-log
process:
value: purchased-component
source: inferred
confidence: high
- id: part:antenna
name: 2.4 GHz chip antenna
material:
value: ceramic
source: observed
confidence: high
evidence:
- src:ct-run-1
process:
value: purchased-component
source: inferred
confidence: high
- id: part:crystal
name: 32 MHz crystal
material:
value: quartz in ceramic package
source: observed
confidence: high
evidence:
- src:markings
process:
value: purchased-component
source: inferred
confidence: high
- id: part:passives
name: Passives kit, about 120 parts
material:
value: MLCC, thick-film resistors, ferrites
source: observed
confidence: medium
evidence:
- src:ct-run-1
note: count from CT, values not identified
process:
value: purchased-component
source: inferred
confidence: high
- id: part:pcb
name: Bare board, 4 layers
material:
value: FR-4, Tg 150
source: inferred
confidence: medium
process:
value: fabricated board
source: inferred
confidence: high
- id: part:retail-box
name: Retail box
material:
value: SBS board, 350 gsm, matte laminate
source: observed
confidence: medium
evidence:
- src:teardown-log
process:
value: printed, die-cut, glued
source: inferred
confidence: high
mass_g:
value: 48.0
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
- id: part:pack-tray
name: Pulp tray
material:
value: moulded pulp
source: observed
confidence: high
evidence:
- src:teardown-log
process:
value: wet-pressed pulp
source: inferred
confidence: medium
mass_g:
value: 14.0
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
- id: part:usb-cable
name: USB-C to USB-A cable, 1 m
material:
value: TPE jacket, copper
source: observed
confidence: high
evidence:
- src:teardown-log
process:
value: purchased-assembly
source: inferred
confidence: high
mass_g:
value: 22.0
unit: g
source: measured
confidence: high
evidence:
- src:caliper-run-1
note: scale, 0.01 g, mean of 30 units
assemblies:
- id: asm:top-sub
name: Top shell with buttons and dome sheet
- id: asm:core
name: Bottom shell with PCBA, stick, battery and haptic
- id: asm:ec-1
name: EC-1, closed unit
- id: asm:packed
name: Packed unit
bom:
- item: asm:packed
parent: null
qty: 1
- item: asm:ec-1
parent: asm:packed
qty: 1
- item: part:retail-box
parent: asm:packed
qty: 1
unit_cost_usd:
value: 0.45
unit: USD
source: inferred
confidence: medium
supplier: sup:pack
- item: part:pack-tray
parent: asm:packed
qty: 1
unit_cost_usd:
value: 0.12
unit: USD
source: inferred
confidence: medium
supplier: sup:pack
- item: part:usb-cable
parent: asm:packed
qty: 1
unit_cost_usd:
value: 0.3
unit: USD
source: inferred
confidence: medium
supplier: sup:pack
- item: asm:top-sub
parent: asm:ec-1
qty: 1
- item: asm:core
parent: asm:ec-1
qty: 1
- item: part:screw-m2x6
parent: asm:ec-1
qty: 4
unit_cost_usd:
value: 0.006
unit: USD
source: inferred
confidence: medium
supplier: sup:fastener
- item: part:rating-label
parent: asm:ec-1
qty: 1
unit_cost_usd:
value: 0.02
unit: USD
source: inferred
confidence: medium
supplier: sup:pack
- item: part:top-shell
parent: asm:top-sub
qty: 1
unit_cost_usd:
value: 0.62
unit: USD
source: inferred
confidence: medium
supplier: sup:shell-moulder
- item: part:light-pipe
parent: asm:top-sub
qty: 1
unit_cost_usd:
value: 0.02
unit: USD
source: inferred
confidence: medium
supplier: sup:shell-moulder
- item: part:button-cap
parent: asm:top-sub
qty: 4
unit_cost_usd:
value: 0.03
unit: USD
source: inferred
confidence: medium
supplier: sup:shell-moulder
- item: part:shoulder-button
parent: asm:top-sub
qty: 2
unit_cost_usd:
value: 0.05
unit: USD
source: inferred
confidence: medium
supplier: sup:shell-moulder
- item: part:dome-sheet
parent: asm:top-sub
qty: 1
unit_cost_usd:
value: 0.09
unit: USD
source: inferred
confidence: medium
supplier: sup:rubber
- item: part:bottom-shell
parent: asm:core
qty: 1
unit_cost_usd:
value: 0.58
unit: USD
source: inferred
confidence: medium
supplier: sup:shell-moulder
- item: part:main-pcba
parent: asm:core
qty: 1
unit_cost_usd:
value: 4.93
unit: USD
source: inferred
confidence: low
note: should-cost; PCBA rolls up its parts plus 0.60 for SMT and test
supplier: sup:ems
- item: part:stick-module
parent: asm:core
qty: 1
unit_cost_usd:
value: 1.35
unit: USD
source: inferred
confidence: medium
supplier: sup:stick-vendor
- item: part:battery
parent: asm:core
qty: 1
unit_cost_usd:
value: 1.1
unit: USD
source: inferred
confidence: medium
supplier: sup:cell-maker
- item: part:haptic-lra
parent: asm:core
qty: 1
unit_cost_usd:
value: 0.38
unit: USD
source: inferred
confidence: medium
supplier: sup:haptic-vendor
- item: part:pcb
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 0.85
unit: USD
source: inferred
confidence: medium
supplier: sup:ems
- item: part:soc
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 1.9
unit: USD
source: inferred
confidence: medium
supplier: sup:chip-distributor
- item: part:imu
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 0.55
unit: USD
source: inferred
confidence: medium
supplier: sup:chip-distributor
- item: part:pmic
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 0.42
unit: USD
source: inferred
confidence: medium
supplier: sup:chip-distributor
- item: part:usb-c
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 0.12
unit: USD
source: inferred
confidence: medium
supplier: sup:chip-distributor
- item: part:antenna
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 0.08
unit: USD
source: inferred
confidence: medium
supplier: sup:chip-distributor
- item: part:crystal
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 0.06
unit: USD
source: inferred
confidence: medium
supplier: sup:chip-distributor
- item: part:passives
parent: part:main-pcba
qty: 1
unit_cost_usd:
value: 0.35
unit: USD
source: inferred
confidence: medium
supplier: sup:chip-distributor
suppliers:
- id: sup:shell-moulder
name:
value: Shell moulder, from tool marks and cavity numbering
source: inferred
confidence: low
region:
value: Dongguan, CN
source: inferred
confidence: low
- id: sup:ems
name:
value: EMS for SMT and the PCBA (fictional)
source: inferred
confidence: low
region:
value: Shenzhen, CN
source: inferred
confidence: low
- id: sup:stick-vendor
name:
value: Stick module vendor, from the module marking EXS-10K
source: inferred
confidence: medium
region:
value: Guangdong, CN
source: inferred
confidence: medium
- id: sup:cell-maker
name:
value: Cell maker, from the cell label
source: inferred
confidence: medium
region:
value: Huizhou, CN
source: observed
confidence: medium
- id: sup:haptic-vendor
name:
value: LRA vendor
source: inferred
confidence: low
region:
value: unknown
source: inferred
confidence: low
- id: sup:fastener
name:
value: Fastener house
source: inferred
confidence: low
region:
value: Dongguan, CN
source: inferred
confidence: low
- id: sup:rubber
name:
value: Silicone moulder
source: inferred
confidence: low
region:
value: Dongguan, CN
source: inferred
confidence: low
- id: sup:chip-distributor
name:
value: Authorised distributor for silicon
source: inferred
confidence: low
region:
value: Shenzhen, CN
source: inferred
confidence: low
- id: sup:pack
name:
value: Packaging and accessories
source: inferred
confidence: low
region:
value: Dongguan, CN
source: inferred
confidence: low
operations:
- id: op:buttons-in
name: Seat light pipe, face buttons and shoulder buttons in top shell
type: place
inputs:
- part:top-shell
- part:light-pipe
- part:button-cap
- part:shoulder-button
output: asm:top-sub
station: sta:a1
method:
value: by hand, shell face-down in nest
source: observed
confidence: medium
evidence:
- src:teardown-log
fixture:
value: top-shell nest
source: inferred
confidence: medium
cycle_time_s:
value: 14
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:dome-place
name: Place dome sheet over the buttons
type: place
inputs:
- asm:top-sub
- part:dome-sheet
output: asm:top-sub
station: sta:a1
method:
value: by hand onto two locating pins
source: observed
confidence: medium
evidence:
- src:teardown-log
fixture:
value: dome locator pins
source: inferred
confidence: medium
cycle_time_s:
value: 6
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:stick-solder
name: Hand-solder stick module to the PCBA (6 pins)
type: solder
inputs:
- part:main-pcba
- part:stick-module
output: asm:core
station: sta:a2
method:
value: hand solder, no-clean flux core wire
source: observed
confidence: medium
evidence:
- src:teardown-log
fixture:
value: PCBA nest with stick square
source: inferred
confidence: medium
cycle_time_s:
value: 22
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:pcba-place
name: Snap PCBA into bottom shell
type: snap-fit
inputs:
- part:bottom-shell
- asm:core
output: asm:core
station: sta:a2
method:
value: two snaps, then press at four bosses
source: observed
confidence: medium
evidence:
- src:teardown-log
cycle_time_s:
value: 6
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:battery-adhere
name: Stick battery into pocket with PSA
type: adhesive
inputs:
- asm:core
- part:battery
output: asm:core
station: sta:a3
method:
value: peel liner, place, press 20 N for 3 s
source: observed
confidence: medium
evidence:
- src:teardown-log
fixture:
value: battery press
source: inferred
confidence: medium
cycle_time_s:
value: 10
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:haptic-place
name: Place LRA and mate its connector
type: connector-mate
inputs:
- asm:core
- part:haptic-lra
output: asm:core
station: sta:a3
method:
value: by hand into rib pocket
source: observed
confidence: medium
evidence:
- src:teardown-log
cycle_time_s:
value: 8
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:battery-mate
name: Mate battery connector
type: connector-mate
inputs:
- asm:core
output: asm:core
station: sta:a3
method:
value: by hand, listen for click
source: observed
confidence: medium
evidence:
- src:teardown-log
cycle_time_s:
value: 5
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:close
name: Close top sub-assembly onto the core
type: snap-fit
inputs:
- asm:core
- asm:top-sub
output: asm:ec-1
station: sta:a4
method:
value: align at USB-C end, rotate closed
source: observed
confidence: medium
evidence:
- src:teardown-log
fixture:
value: closing fixture
source: inferred
confidence: medium
cycle_time_s:
value: 8
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:screw
name: Drive four M2 screws to 0.18 N·m
type: screw
inputs:
- asm:ec-1
- part:screw-m2x6
output: asm:ec-1
station: sta:a4
method:
value: torque driver, cross pattern
source: observed
confidence: medium
evidence:
- src:teardown-log
fixture:
value: closing fixture
source: inferred
confidence: medium
cycle_time_s:
value: 16
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:flash
name: Flash the test image, then RF test
type: flash
inputs:
- asm:ec-1
output: asm:ec-1
station: sta:t1
method:
value: USB-C pogo, then radiated test in shield box
source: inferred
confidence: medium
fixture:
value: USB-C pogo fixture
source: inferred
confidence: medium
cycle_time_s:
value: 30
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:stick-cal
name: Stick centre and range calibration
type: ext:controller:stick-calibrate
inputs:
- asm:ec-1
output: asm:ec-1
station: sta:t2
method:
value: robot sweeps the stick to 8 points and centre
source: inferred
confidence: medium
fixture:
value: stick robot nest
source: inferred
confidence: medium
cycle_time_s:
value: 15
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:functional
name: Buttons, IMU, haptics and LED
type: test
inputs:
- asm:ec-1
output: asm:ec-1
station: sta:t2
method:
value: press head, 90 degree turntable step, LRA current
source: inferred
confidence: medium
cycle_time_s:
value: 12
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:cosmetic
name: Cosmetic and gap check
type: inspect
inputs:
- asm:ec-1
output: asm:ec-1
station: sta:t3
method:
value: camera arch plus feeler gauge at shoulder buttons
source: inferred
confidence: medium
cycle_time_s:
value: 12
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:charge
name: Charge current and battery check
type: test
inputs:
- asm:ec-1
output: asm:ec-1
station: sta:t4
method:
value: 5 V in, measure charge current and cell voltage
source: inferred
confidence: medium
fixture:
value: 8-up rack
source: inferred
confidence: medium
cycle_time_s:
value: 20
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:label
name: Apply rating label
type: label
inputs:
- asm:ec-1
- part:rating-label
output: asm:ec-1
station: sta:p1
method:
value: print and apply, scan serial
source: observed
confidence: medium
cycle_time_s:
value: 6
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
- id: op:pack
name: Pack with tray and cable
type: pack
inputs:
- asm:ec-1
- part:retail-box
- part:pack-tray
- part:usb-cable
output: asm:packed
station: sta:p1
method:
value: tray, unit, cable, close, weigh
source: observed
confidence: medium
cycle_time_s:
value: 14
unit: s
source: inferred
confidence: low
note: time-study estimate on the synthetic build
stations:
- id: sta:iqc-1
name: Incoming inspection
type: iqc
equipment:
- value: caliper and pin gauges
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: light booth
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: battery OCV meter
source: inferred
confidence: low
note: implied by the design and the tests the product needs
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/IQC1
isa95_work_center: EC1-Cell/IQC1
data_interface: none
- id: sta:a1
name: Top-shell sub-assembly
type: assembly
equipment:
- value: nest fixture for the top shell
source: observed
confidence: medium
evidence: &id001
- src:teardown-log
- src:photos
- value: dome sheet locator
source: observed
confidence: medium
evidence: *id001
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/A1
isa95_work_center: EC1-Cell/A1
data_interface: none
- id: sta:a2
name: Stick and PCBA to bottom shell
type: assembly
equipment:
- value: temperature-controlled soldering iron, 350 C
source: observed
confidence: medium
evidence: *id001
- value: fume extractor
source: observed
confidence: medium
evidence: *id001
- value: PCBA nest
source: observed
confidence: medium
evidence: *id001
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/A2
isa95_work_center: EC1-Cell/A2
data_interface: none
- id: sta:a3
name: Battery and haptic
type: assembly
equipment:
- value: PSA liner peeler
source: observed
confidence: medium
evidence: *id001
- value: battery press, 20 N
source: observed
confidence: medium
evidence: *id001
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/A3
isa95_work_center: EC1-Cell/A3
data_interface: none
- id: sta:a4
name: Close and screw
type: assembly
equipment:
- value: closing fixture
source: observed
confidence: medium
evidence: *id001
- value: electric torque driver, 0.18 N·m, with count check
source: observed
confidence: medium
evidence: *id001
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/A4
isa95_work_center: EC1-Cell/A4
data_interface: none
device_references:
- device:
value: electric torque driver with count check
source: observed
confidence: medium
evidence:
- src:teardown-log
spec: mhs-preview
measures:
- name: final torque
unit: N·m
- name: angle
unit: deg
adjustable:
- name: target torque
unit: N·m
min: 0.1
max: 0.3
safety_limits:
- name: max torque
limit: 0.3
unit: N·m
- id: sta:t1
name: Flash test image and RF test
type: test
equipment:
- value: RF shield box
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: BLE tester
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: USB-C pogo fixture
source: inferred
confidence: low
note: implied by the design and the tests the product needs
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/T1
isa95_work_center: EC1-Cell/T1
data_interface: ipc-cfx
device_references:
- device:
value: BLE tester in RF shield box
source: inferred
confidence: medium
spec: mhs-preview
measures:
- name: TX power
unit: dBm
- name: RSSI
unit: dBm
adjustable:
- name: channel
min: 0
max: 39
- id: sta:t2
name: Functional test and stick calibration
type: test
equipment:
- value: stick actuation robot
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: button press head
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: IMU turntable
source: inferred
confidence: low
note: implied by the design and the tests the product needs
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/T2
isa95_work_center: EC1-Cell/T2
data_interface: ipc-cfx
device_references:
- device:
value: stick actuation robot
source: inferred
confidence: medium
spec: mhs-preview
measures:
- name: stick position
unit: '% of full scale'
adjustable:
- name: deflection angle
unit: deg
min: 0
max: 28
safety_limits:
- name: max push force
limit: 8
unit: N
- id: sta:t3
name: Cosmetic and gap check
type: fqc
equipment:
- value: camera arch, 4 cameras
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: feeler gauges 0.10 / 0.30 mm
source: inferred
confidence: low
note: implied by the design and the tests the product needs
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/T3
isa95_work_center: EC1-Cell/T3
data_interface: ipc-cfx
- id: sta:t4
name: Charge and battery test
type: test
equipment:
- value: programmable USB-C load
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: 8-up charge rack
source: inferred
confidence: low
note: implied by the design and the tests the product needs
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/T4
isa95_work_center: EC1-Cell/T4
data_interface: ipc-cfx
- id: sta:p1
name: Label and pack
type: pack
equipment:
- value: label printer and applicator
source: observed
confidence: medium
evidence: *id001
- value: pack bench, scale
source: observed
confidence: medium
evidence: *id001
operators:
value: 2
source: inferred
confidence: medium
layout_usd_prim: /Line/P1
isa95_work_center: EC1-Cell/P1
data_interface: none
- id: sta:oqc-1
name: Outgoing audit
type: oqc
equipment:
- value: full functional test set
source: inferred
confidence: low
note: implied by the design and the tests the product needs
- value: drop tester (sampled)
source: inferred
confidence: low
note: implied by the design and the tests the product needs
operators:
value: 1
source: inferred
confidence: medium
layout_usd_prim: /Line/OQC1
isa95_work_center: EC1-Cell/OQC1
data_interface: none
inspection_plans:
- id: insp:shell-iqc
station: sta:iqc-1
stage: iqc
item: part:top-shell
characteristic: Length, width and stick hole diameter; cosmetic grade A
method:
value: caliper and pin gauge; light booth
source: inferred
confidence: medium
sampling:
standard: ANSI/ASQ Z1.4
inspection_level: II
aql: 1.0
lot_size_range:
- 1201
- 3200
sample_size: 125
basis:
value: general inspection level II, normal inspection
source: inferred
confidence: medium
- id: insp:stick-iqc
station: sta:iqc-1
stage: iqc
item: part:stick-module
characteristic: Centre return and full travel resistance
method:
value: fixture with ohmmeter
source: inferred
confidence: medium
sampling:
standard: ANSI/ASQ Z1.4
inspection_level: II
aql: 0.65
lot_size_range:
- 1201
- 3200
sample_size: 125
basis:
value: general inspection level II, normal inspection
source: inferred
confidence: medium
- id: insp:cell-iqc
station: sta:iqc-1
stage: iqc
item: part:battery
characteristic: Open-circuit voltage 3.75 to 3.90 V; thickness at most 6.1 mm
method:
value: OCV meter and caliper
source: inferred
confidence: medium
sampling:
standard: ANSI/ASQ Z1.4
inspection_level: II
aql: 0.4
lot_size_range:
- 1201
- 3200
sample_size: 125
basis:
value: general inspection level II, normal inspection
source: inferred
confidence: medium
- id: insp:screw-audit
station: sta:a4
stage: ipqc
item: op:screw
characteristic: Breakaway torque 0.16 to 0.22 N·m
method:
value: torque audit gauge, 5 units per hour
source: inferred
confidence: medium
sampling:
standard: other
sample_size: 5
- id: insp:cosmetic-100
station: sta:t3
stage: fqc
item: asm:ec-1
characteristic: No scratch over 0.3 mm in zone A; shoulder gap 0.10 to 0.30 mm
method:
value: camera arch and feeler gauge
source: inferred
confidence: medium
sampling:
standard: 100%
- id: insp:oqc
station: sta:oqc-1
stage: oqc
item: asm:packed
characteristic: Full functional, pack contents, label, drop 1.2 m on 1 unit per lot
method:
value: full test set
source: inferred
confidence: medium
sampling:
standard: ANSI/ASQ Z1.4
inspection_level: II
aql: 0.65
lot_size_range:
- 501
- 1200
sample_size: 80
basis:
value: general inspection level II, normal inspection
source: inferred
confidence: medium
tests:
- id: test:flash-ok
station: sta:t1
name: Test image flashed and verified
measures: image checksum
- id: test:rf-power
station: sta:t1
name: Radiated output power
measures: TX power at 2440 MHz
lower:
value: -6.0
unit: dBm
source: inferred
confidence: medium
upper:
value: 4.0
unit: dBm
source: inferred
confidence: medium
- id: test:rf-rssi
station: sta:t1
name: Receive sensitivity
measures: RSSI from reference tag at 1 m
lower:
value: -70.0
unit: dBm
source: inferred
confidence: medium
- id: test:stick-centre
station: sta:t2
name: Stick centre at rest, after calibration
measures: centre offset
upper:
value: 1.0
unit: '% of full scale'
source: inferred
confidence: medium
- id: test:stick-range
station: sta:t2
name: Stick range, each axis
measures: full-scale reach
lower:
value: 96.0
unit: '% of full scale'
source: inferred
confidence: medium
- id: test:button-force
station: sta:t2
name: Face button actuation force
measures: force at contact
lower:
value: 150.0
unit: gf
source: inferred
confidence: medium
upper:
value: 210.0
unit: gf
source: inferred
confidence: medium
- id: test:imu-bias
station: sta:t2
name: Gyro zero-rate bias
measures: bias, each axis
upper:
value: 2.0
unit: deg/s
source: inferred
confidence: medium
- id: test:haptic-current
station: sta:t2
name: LRA drive current
measures: RMS current at 170 Hz
lower:
value: 40.0
unit: mA
source: inferred
confidence: medium
upper:
value: 90.0
unit: mA
source: inferred
confidence: medium
- id: test:charge-current
station: sta:t4
name: Charge current at 5 V
measures: input current
lower:
value: 280.0
unit: mA
source: inferred
confidence: medium
upper:
value: 360.0
unit: mA
source: inferred
confidence: medium
- id: test:cell-voltage
station: sta:t4
name: Cell voltage after 20 s charge
measures: cell voltage
lower:
value: 3.7
unit: V
source: inferred
confidence: medium
upper:
value: 4.05
unit: V
source: inferred
confidence: medium
- id: test:shoulder-gap
station: sta:t3
name: Gap at shoulder buttons
measures: feeler gauge
lower:
value: 0.1
unit: mm
source: inferred
confidence: medium
upper:
value: 0.3
unit: mm
source: inferred
confidence: medium
pfmea:
- id: fm:stick-flux
operation: op:stick-solder
failure_mode: Flux residue wicks into stick potentiometer
effect: Stick drift in the field
cause: Too much flux, iron dwell over 3 s
severity: 7
occurrence: 5
detection: 7
evidence:
- src:repair-guide
- src:reviews
- id: fm:stick-cold-joint
operation: op:stick-solder
failure_mode: Cold or cracked solder joint on stick pins
effect: Intermittent stick axis
cause: Iron temperature or dwell too low
severity: 7
occurrence: 3
detection: 4
evidence:
- src:ct-run-1
- id: fm:pcba-boss-crack
operation: op:pcba-place
failure_mode: Board pressed onto its ledges cracks a support rib
effect: Loose PCBA, rattle
cause: Press force not controlled
severity: 5
occurrence: 2
detection: 6
evidence:
- src:teardown-log
- id: fm:cell-misplace
operation: op:battery-adhere
failure_mode: Battery placed off-pocket
effect: Pinched cell at close, swelling risk
cause: No locating feature for the cell
severity: 9
occurrence: 2
detection: 5
evidence:
- src:ct-run-1
- id: fm:haptic-reversed
operation: op:haptic-place
failure_mode: LRA connector mated off by one pin
effect: No haptics
cause: Unkeyed 2-pin connector
severity: 5
occurrence: 2
detection: 3
evidence:
- src:teardown-log
- id: fm:battery-unseat
operation: op:battery-mate
failure_mode: Battery connector half-seated
effect: Dead unit after drop
cause: No seat check, tight z-height under the top shell
severity: 8
occurrence: 4
detection: 6
evidence:
- src:ct-run-1
- src:reviews
- id: fm:pinched-wire
operation: op:close
failure_mode: Battery wire pinched between shells
effect: Short, field return, safety
cause: Wire routed over the boss
severity: 9
occurrence: 2
detection: 5
evidence:
- src:ct-run-1
- id: fm:screw-strip
operation: op:screw
failure_mode: Screw strips the boss
effect: Loose shell, gap
cause: Torque too high or cross-threaded
severity: 5
occurrence: 3
detection: 3
evidence:
- src:teardown-log
- id: fm:rf-low
operation: op:flash
failure_mode: Low radiated power
effect: Short range in the field
cause: LRA placed against the antenna keep-out
severity: 6
occurrence: 3
detection: 2
evidence:
- src:eol-sample
- id: fm:stick-cal-fail
operation: op:stick-cal
failure_mode: Calibration out of range
effect: Rework or scrap
cause: Stick module centre offset beyond 4%
severity: 4
occurrence: 4
detection: 2
evidence:
- src:eol-sample
- id: fm:gap-high
operation: op:cosmetic
failure_mode: Shoulder gap over 0.30 mm
effect: Cosmetic complaint, dust ingress
cause: Shell warp at the shoulder wall
severity: 4
occurrence: 5
detection: 4
evidence:
- src:caliper-run-1
- src:reviews
- id: fm:wrong-label
operation: op:label
failure_mode: Label serial does not match the unit
effect: Traceability lost
cause: Label printed ahead of unit
severity: 4
occurrence: 2
detection: 3
evidence:
- src:teardown-log
design_intent:
targets:
- characteristic: gap
where:
- part:top-shell
target:
value: 0.2
unit: mm
source: inferred
confidence: low
lower:
value: 0.1
unit: mm
source: inferred
confidence: low
upper:
value: 0.3
unit: mm
source: inferred
confidence: low
priority: should
owner: industrial-design
rationale: Even, tight seam at the shoulder buttons
- characteristic: button-force
where:
- part:button-cap
target:
value: 180
unit: gf
source: measured
confidence: medium
lower:
value: 150
unit: gf
source: measured
confidence: medium
upper:
value: 210
unit: gf
source: measured
confidence: medium
priority: should
owner: industrial-design
rationale: Crisp, light press
- characteristic: button-travel
where:
- part:button-cap
target:
value: 0.8
unit: mm
source: measured
confidence: medium
lower:
value: 0.6
unit: mm
source: measured
confidence: medium
upper:
value: 1.0
unit: mm
source: measured
confidence: medium
priority: nice
owner: industrial-design
- characteristic: weight
where:
- asm:ec-1
target:
value: 69
unit: g
source: measured
confidence: high
upper:
value: 74
unit: g
source: measured
confidence: high
priority: must
owner: product
rationale: Light enough for long sessions; set from the parts below
- characteristic: battery-life
where:
- part:battery
target:
value: 30
unit: h
source: inferred
confidence: medium
lower:
value: 25
unit: h
source: inferred
confidence: medium
priority: must
owner: product
rationale: A week of evenings on one charge
- characteristic: drop-height
where:
- asm:ec-1
target:
value: 1.2
unit: m
source: inferred
confidence: medium
priority: must
owner: reliability
- characteristic: thickness
where:
- asm:ec-1
target:
value: 22
unit: mm
source: measured
confidence: high
upper:
value: 23
unit: mm
source: measured
confidence: high
priority: should
owner: industrial-design
issues:
- id: iss:stick-drift-flux
title: Stick drift traced to flux under the potentiometer
visibility: public
failure_mode: ext:controller:stick-drift
part_types:
- sensor
processes:
- solder
observed_on:
- field
- simulated
detected_at:
- field
- test
conditions: Hand soldering with flux-core wire next to an open potentiometer housing; worse after months of use
yield_impact:
value: 1.2
unit: '%'
source: inferred
confidence: medium
evidence:
- src:reviews
- src:repair-guide
note: field return share attributed to drift in the review sample
root_cause:
value: Flux migrates into the carbon track and changes wiper resistance
source: inferred
confidence: medium
evidence:
- src:ct-run-1
- src:repair-guide
resolutions:
- fix_type: design-change
description: Replace soldered pins with an FPC connector on the stick module
status: proposed
operations:
- op:stick-solder
- fix_type: sop-update
description: Cap iron dwell at 2 s, no extra flux, inspect with 10x loupe
status: implemented
operations:
- op:stick-solder
implemented_on: '2026-09-14'
implementation_evidence:
- kind: sop-revision
source: src:teardown-log
note: SOP A2 rev C, step 3
yield_before:
value: 97.8
unit: '%'
source: inferred
confidence: low
yield_after:
value: 98.6
unit: '%'
source: inferred
confidence: low
parts:
- part:stick-module
- part:main-pcba
operations:
- op:stick-solder
pfmea:
- fm:stick-flux
tags:
- solder
- field-return
- id: iss:battery-unseat
title: Battery connector unseats after a 1.2 m drop
visibility: public
failure_mode: connector-unseat
part_types:
- fpc-connector
- battery
processes:
- connector-mate
observed_on:
- simulated
- dvt
detected_at:
- reliability-test
conditions: Tight z-height over the connector; the top shell rib lands 0.3 mm above it
yield_impact:
value: 0.9
unit: '%'
source: inferred
confidence: low
evidence:
- src:ct-run-1
note: drop-test fallout in the simulated build
root_cause:
value: No preload on the connector and no seat check at mating
source: inferred
confidence: medium
evidence:
- src:ct-run-1
resolutions:
- fix_type: fixture-change
description: Closing fixture presses the connector while the shell closes
status: proposed
operations:
- op:close
- fix_type: sop-update
description: Tug test after mating, 2 N, at sta:a3
status: proposed
operations:
- op:battery-mate
parts:
- part:battery
- part:main-pcba
operations:
- op:battery-mate
- op:close
pfmea:
- fm:battery-unseat
tags:
- tight-space
- drop
- id: iss:shoulder-gap
title: Shoulder-button gap opens past 0.30 mm on cavity 2
visibility: embargoed
embargo_until: '2028-06-01'
failure_mode: gap-flush
part_types:
- housing
- button
processes:
- inspect
observed_on:
- pvt
detected_at:
- fqc
conditions: Cavity 2 of the top-shell tool; worse in the first hour after a mould start
yield_impact:
value: 1.7
unit: '%'
source: inferred
confidence: low
evidence:
- src:caliper-run-1
root_cause:
value: Uneven cooling bows the shoulder wall outward on cavity 2
source: inferred
confidence: low
evidence:
- src:caliper-run-1
resolutions:
- fix_type: process-change
description: Raise mould temperature 8 C and extend cooling 2 s on cavity 2
status: trialled
operations:
- op:cosmetic
yield_before:
value: 98.3
unit: '%'
source: inferred
confidence: low
yield_after:
value: 99.1
unit: '%'
source: inferred
confidence: low
parts:
- part:top-shell
- part:shoulder-button
operations:
- op:cosmetic
pfmea:
- fm:gap-high
tags:
- tooling
- cosmetic
- id: iss:rf-detune
title: RF power low when the LRA sits against the antenna keep-out
visibility: public
failure_mode: rf-detune
part_types:
- antenna
- motor-haptic
processes:
- connector-mate
observed_on:
- simulated
detected_at:
- test
conditions: The LRA pocket allows 2 mm of play toward the antenna
yield_impact:
value: 0.6
unit: '%'
source: inferred
confidence: low
evidence:
- src:eol-sample
root_cause:
value: Metal LRA can within 5 mm of the chip antenna detunes it
source: inferred
confidence: medium
resolutions:
- fix_type: design-change
description: Add a rib so the LRA can't move toward the antenna
status: proposed
operations:
- op:haptic-place
parts:
- part:haptic-lra
- part:antenna
operations:
- op:haptic-place
pfmea:
- fm:rf-low
tags:
- rf
- placement
variants:
objectives:
- metric: yield.rty
direction: max
- metric: cost.cost_per_good_unit
direction: min
- metric: throughput.cycle_time
direction: min
constraints:
- takt 36 s (2,000 units a day over two 10-hour shifts)
- headcount at most 12
- no single new tool over 25,000 USD
baseline:
scores:
yield:
fpy_by_station:
sta:a2:
value: 0.992
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
sta:a3:
value: 0.996
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
sta:a4:
value: 0.99
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
sta:t1:
value: 0.985
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
sta:t2:
value: 0.978
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
sta:t3:
value: 0.983
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
sta:t4:
value: 0.995
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
rty:
value: 0.922
origin: simulated
engine: monte-carlo
runs: 20000
interval:
- 0.905
- 0.935
confidence: low
top_failure_modes:
- failure_mode: ext:controller:stick-drift
share:
value: 0.24
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
issue: iss:stick-drift-flux
pfmea: fm:stick-flux
- failure_mode: connector-unseat
share:
value: 0.18
origin: simulated
engine: mujoco
runs: 2000
confidence: low
issue: iss:battery-unseat
pfmea: fm:battery-unseat
- failure_mode: gap-flush
share:
value: 0.16
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
issue: iss:shoulder-gap
pfmea: fm:gap-high
throughput:
cycle_time:
value: 30
unit: s
origin: estimated
engine: analytic
confidence: low
note: slowest station from time studies; needs the discrete-event simulator
takt:
value: 36
unit: s
origin: estimated
engine: analytic
confidence: high
bottleneck_station: sta:t1
headcount: 11
cost:
cost_per_good_unit:
value: 1.92
unit: USD
origin: estimated
engine: analytic
confidence: low
note: conversion cost per good unit, including scrap and rework
experience:
weight:
value: 69.4
unit: g
origin: measured
confidence: medium
evidence:
- src:caliper-run-1
gap_flush_consistency:
value: 0.0493
unit: mm, 1 sigma
origin: measured
confidence: medium
evidence:
- src:caliper-run-1
predicted_field_return_rate:
value: 0.031
origin: estimated
confidence: low
review_sentiment:
value: 0.42
unit: -1 to 1
origin: measured
engine: review-analysis
confidence: low
evidence:
- src:reviews
pareto:
on_frontier: true
candidates:
- id: var:split-t1
name: Second RF shield box at T1
kind: equipment
base: baseline
description: Two shield boxes so flashing and RF test run in parallel
changes:
- action: add
target:
- sta:t1
description: Second shield box and BLE tester
generated_by:
method: agent
engine: analytic
created: '2026-10-30'
scores:
yield:
rty:
value: 0.922
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
throughput:
cycle_time:
value: 25
unit: s
origin: estimated
engine: analytic
confidence: low
bottleneck_station: sta:t2
headcount: 11
cost:
cost_per_good_unit:
value: 1.98
unit: USD
origin: estimated
engine: analytic
confidence: low
capex:
value: 9800
unit: USD
origin: estimated
engine: analytic
confidence: medium
pareto:
on_frontier: true
- id: var:stick-connector
name: FPC connector for the stick instead of hand soldering
kind: design-change
base: baseline
description: Stick module ships with a flex tail; a ZIF connector replaces six hand-soldered pins
addresses:
- iss:stick-drift-flux
- fm:stick-flux
changes:
- action: replace
target:
- op:stick-solder
description: Solder step becomes a connector mate
- action: modify
target:
- part:stick-module
description: Module with flex tail, +0.12 USD
generated_by:
method: agent
engine: monte-carlo
created: '2026-10-30'
scores:
yield:
rty:
value: 0.936
origin: simulated
engine: monte-carlo
runs: 20000
interval:
- 0.92
- 0.95
confidence: low
throughput:
cycle_time:
value: 28
unit: s
origin: estimated
engine: analytic
confidence: low
headcount: 11
cost:
cost_per_good_unit:
value: 1.95
unit: USD
origin: estimated
engine: analytic
confidence: low
experience:
predicted_field_return_rate:
value: 0.019
origin: estimated
confidence: low
pareto:
on_frontier: true
- id: var:preload-close
name: Preload fixture and tug test for the battery connector
kind: fixture-sequence
base: baseline
description: Closing fixture holds the connector down; a 2 N tug test after mating
addresses:
- iss:battery-unseat
- fm:battery-unseat
changes:
- action: modify
target:
- op:close
description: Preload pad in the closing fixture
- action: modify
target:
- op:battery-mate
description: Add tug test
generated_by:
method: agent
engine: mujoco
created: '2026-10-30'
scores:
yield:
rty:
value: 0.932
origin: simulated
engine: monte-carlo
runs: 20000
interval:
- 0.915
- 0.945
confidence: low
throughput:
cycle_time:
value: 31
unit: s
origin: estimated
engine: analytic
confidence: low
headcount: 11
cost:
cost_per_good_unit:
value: 1.96
unit: USD
origin: estimated
engine: analytic
confidence: low
pareto:
on_frontier: false
dominated_by:
- var:stick-connector
- id: var:gap-tight
name: Tighten the shoulder gap to 0.10 mm
kind: design-change
base: baseline
description: Industrial design asks for a tighter, more premium seam
design_intent:
targets:
- characteristic: gap
where:
- part:top-shell
target:
value: 0.1
unit: mm
source: inferred
confidence: low
upper:
value: 0.15
unit: mm
source: inferred
confidence: low
priority: should
owner: industrial-design
changes:
- action: modify
target:
- part:top-shell
description: Tighter tool tolerance and a cooling change on the shoulder wall
generated_by:
method: agent
engine: monte-carlo
created: '2026-10-30'
scores:
yield:
rty:
value: 0.874
origin: simulated
engine: monte-carlo
runs: 20000
interval:
- 0.85
- 0.895
confidence: low
throughput:
cycle_time:
value: 30
unit: s
origin: estimated
engine: analytic
confidence: low
cost:
cost_per_good_unit:
value: 2.6
unit: USD
origin: estimated
engine: analytic
confidence: low
experience:
gap_flush_consistency:
value: 0.03
unit: mm, 1 sigma
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
cosmetic_defect_rate:
value: 0.061
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
pareto:
on_frontier: false
dominated_by:
- baseline
- var:split-t1
- var:stick-connector
- id: var:connector-and-preload
name: Stick connector plus battery preload
kind: mixed
base: baseline
description: Both fixes together
addresses:
- iss:stick-drift-flux
- iss:battery-unseat
changes:
- action: replace
target:
- op:stick-solder
description: As var:stick-connector
- action: modify
target:
- op:close
- op:battery-mate
description: As var:preload-close
generated_by:
method: agent
engine: monte-carlo
created: '2026-10-31'
scores:
yield:
rty:
value: 0.947
origin: simulated
engine: monte-carlo
runs: 20000
interval:
- 0.93
- 0.96
confidence: low
throughput:
cycle_time:
value: 31
unit: s
origin: estimated
engine: analytic
confidence: low
headcount: 11
cost:
cost_per_good_unit:
value: 1.99
unit: USD
origin: estimated
engine: analytic
confidence: low
ramp:
changes_needed:
value: 3
origin: estimated
confidence: medium
pareto:
on_frontier: true
recommended:
variant: var:connector-and-preload
rationale: Highest simulated yield, and it closes the two largest failure modes, which together make up 42% of fallout
tradeoffs: 0.07 USD more per good unit and 1 s slower than baseline, still inside the 36 s takt; T1 stays the bottleneck
tradeoffs:
- id: tr:gap-tighten
characteristic: gap
from:
value: 0.2
unit: mm
source: inferred
confidence: low
to:
value: 0.1
unit: mm
source: inferred
confidence: low
variant: var:gap-tight
against: baseline
yield_delta:
value: -0.048
unit: RTY
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
cost_per_unit_delta:
value: 0.68
unit: USD
origin: estimated
engine: analytic
confidence: low
other_deltas:
experience.cosmetic_defect_rate:
value: 0.044
origin: simulated
engine: monte-carlo
runs: 20000
confidence: low
experience_effect: A tighter seam that reads as more premium, for about 5 points of yield and 0.68 USD a unit
decision:
status: rejected
by: product (fictional)
'on': '2026-10-31'
note: Not worth the yield at this price point
engine_notes: Yield and failure shares come from Monte Carlo over the measured spreads and MuJoCo drop runs. Cycle time
and line balance are estimates until the discrete-event simulator exists.
ext:
battery:
cells:
- part: part:battery
chemistry:
value: Li-ion polymer
source: observed
confidence: high
evidence:
- src:markings
form: pouch
nominal_voltage_v:
value: 3.7
unit: V
source: observed
confidence: high
evidence:
- src:markings
capacity_mah:
value: 600
unit: mAh
source: observed
confidence: high
evidence:
- src:markings
protection_circuit:
value: single-cell protection board on the tab
source: observed
confidence: high
evidence:
- src:teardown-log
controller:
inputs:
- id: in:stick-l
kind: stick
part: part:stick-module
sensing:
value: potentiometric, two axes
source: observed
confidence: high
evidence:
- src:teardown-log
- src:ct-run-1
- id: in:btn-a
kind: button
part: part:button-cap
sensing:
value: carbon pill on silicone dome
source: observed
confidence: high
evidence:
- src:teardown-log
actuation_force_gf:
value: 184.0
unit: gf
source: measured
confidence: medium
evidence:
- src:eol-sample
- id: in:btn-b
kind: button
part: part:button-cap
sensing:
value: carbon pill on silicone dome
source: observed
confidence: high
evidence:
- src:teardown-log
actuation_force_gf:
value: 179.0
unit: gf
source: measured
confidence: medium
evidence:
- src:eol-sample
- id: in:btn-x
kind: button
part: part:button-cap
sensing:
value: carbon pill on silicone dome
source: observed
confidence: high
evidence:
- src:teardown-log
actuation_force_gf:
value: 189.0
unit: gf
source: measured
confidence: medium
evidence:
- src:eol-sample
- id: in:btn-y
kind: button
part: part:button-cap
sensing:
value: carbon pill on silicone dome
source: observed
confidence: high
evidence:
- src:teardown-log
actuation_force_gf:
value: 177.0
unit: gf
source: measured
confidence: medium
evidence:
- src:eol-sample
- id: in:shoulder-l
kind: button
part: part:shoulder-button
sensing:
value: tact switch on the PCBA
source: observed
confidence: high
evidence:
- src:teardown-log
- id: in:shoulder-r
kind: button
part: part:shoulder-button
sensing:
value: tact switch on the PCBA
source: observed
confidence: high
evidence:
- src:teardown-log
- id: in:gyro
kind: gyro
part: part:imu
sensing:
value: 6-axis MEMS
source: observed
confidence: high
evidence:
- src:markings
haptics:
value: 10 mm LRA, 170 Hz
source: observed
confidence: high
evidence:
- src:teardown-log