Circuit Board Design Process Checklist
(Note: This is intended as an optional checklist, not as a mandatory process to be robotically applied)

Disciplines:

Electrical (analog, digital, software)
Mechanical (it has to fit)
Manufacturing (somebody has to make it)
Test Engineering (remember self test)
Material Engineering (are these the right parts?)
Purchasing (can you get the parts, and how much do they cost?)
Service (or is it disposable?)
Technical Publications
Regulatory (Safety, EMC, FDA, EPA)
Customer (or closest approximation)

Issues for Initial Review

confirmation of customer requirements (what do they really want?)
ergonomics
performance
cost
timing
size
mounting
manufacturing process / technology
environmental
serviceability
reliability requirements
power supply/distribution scheme
harnessing scheme
grounding & shielding scheme
EMC requirements
product safety requirements
thermal requirements & airflow
connector selection/standardization

Documentation Requirements Review

schematic structure
labeling conventions

service
netlist
manufacturing

part field/BOM conventions
alternate or noload part conventions

System Design

create block diagram & theory of operation
FMEA (Failure Mode Effects Analysis) If you are going to do it, this is the time to start
design specifications

System Review Meeting

review block diagram with appropriate disciplines

Subsystem Design

create block diagram & theory of operation
simulate/analyze/test
obtain component specifications / datasheets
create schematics
generate BOM
calculate MTBF (Mean Time Between Failures)
get parts
build prototypes (copper prototypes advised)
write test plan for prototypes
test prototypes

Subsystem Review

review susbsytem design with appropriate disciplines
review components versus stress factors & derating scheme

Documentation Cleanup

BOM
Netlist
Labeling

Placement

mounting
connectors
heatsinks
sockets

Placement Review

Use 1:1 plots to make sure components fit
check fit of board to mounting location
check location of decoupling and filtering components
check for clearance of heatsinks & airflow to heatsinks
manufacturablity of bare board and assembly

Netlist Verification

power pins (check that all are connected)
package pin numbering (triple check SOT23s)
connector pin numbering (watch out for mirroring)

Routing

trace size & spacing for current and safety
layer assignment for impedance control & shielding
be very careful with plane partitioning schemes

Routing Review

trace size and spacing
planes, partitions and traces
safety warnings
test pads
solder mask
silk screening

Photo-Plot Review

don't trust the photo-plotter

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