Beginning with the customer’s documented needs, clearly and unambiguously define and document the project problem or “challenge.” At the very least, cover performance specifications, system interfacing and integration, qualification metrics, deliverables and schedule.

When generating specifications, address all requirements with safe margin. Review the criteria for margin that is unjustified or too costly. Iterate this process, and where ambiguous or break-even, err in the direction of overspecification.

When designing a solution, meet or exceed specifications. Balance margin or safety against cost and delivery trade-offs. When ambiguous or break-even, overdesign.

Address product manufacture and assembly processes and techniques during the design phase. Design in self-assembly, orientation keying, tooling clearance, assembly fixturing. Eliminate or minimize fasteners, number of parts, custom parts and assembly steps.

Address product performance qualification during the design phase. Design in self testing, test fixturing, HW and SW “hooks” that facilitate testing by reducing test time and increasing accuracy.

Where practical, provide degrees of freedon that allow the current product to be a testbed for future products. This gives the prototyping stage a head start with faster turnaround and realistic hardware.

During the design phase consider potential specification changes. Design in HW and SW “hooks” for added flexibility that doesn’t impact product performance or cost. Design in work-arounds for component obsolescence and/or upgrades.