pm-hardware

Review a bill of materials for cost, risk, and supply exposure — cost rollup, top-10 cost drivers, single-source and EOL risk, MOQ vs forecast mismatch, cost-down candidates, and tariff/logistics sensitivity. Use when asked to review a BOM, find cost-down opportunities, check component sourcing risk, or sanity-check BOM cost against target. Produces a structured BOM review with a cost driver Pareto, risk flags per line, and a prioritised cost-down list.

Run an NPI phase-gate review for EVT, DVT, or PVT — exit criteria per phase, open-issue triage, yield readout, waiver discipline, and a go/no-go call. Use when asked to run a gate review, decide EVT exit or DVT entry, review build results, assess whether to proceed to the next build, or triage open issues before a phase gate. Produces a gate review document with criteria scoring, waiver register, yield analysis, and a defensible go/conditional-go/no-go recommendation.

Write a factory acceptance test (FAT) plan or report — test coverage matrix against spec, AQL sampling plan, pass/fail criteria, golden-sample handling, deviation log, and sign-off structure. Use when asked to write a FAT plan, define outgoing quality inspection, set AQL levels, prepare for a factory acceptance or pre-shipment inspection, or document FAT results. Produces a complete FAT plan or report with sampling tables, defect classification, and a sign-off block.

Write a PRD for a physical hardware product — target cost (BOM and landed), industrial design constraints, regulatory certifications, reliability targets, serviceability, packaging, and forecast assumptions. Use when asked to write a hardware PRD, spec a new device, define requirements for a physical product, or kick off an NPI program. Produces a complete hardware PRD with a cost stack, cert matrix, reliability spec, and EVT/DVT/PVT milestone targets.

Turn field returns into a structured failure-analysis report — RMA triage taxonomy (NTF vs real failures), Pareto by verified failure mode, 8D-style containment→root-cause→corrective-action structure, and cost-of-quality framing. Use when asked to analyse RMA data, investigate field returns, run failure analysis on returned units, write an 8D report, or figure out why return rates are climbing. Produces a failure-analysis report with a triage-clean Pareto, 8D actions, and the cost case for fixing each mode.

Assess an injection-mold or production tooling decision before cutting steel — soft vs hard tooling tradeoff, tool life vs forecast, cavitation math, T1 sample timeline, cost of design changes after tooling, and kill criteria. Use when asked whether to kick off tooling, choose soft vs hard tools, size cavities, review a tooling quote, or assess the risk of tooling before the design is frozen. Produces a tooling risk assessment with capacity math, a decision recommendation, and explicit kill criteria.