How to think about engineered solutions?

Rapid prototyping can be an accelerator for hardware or embedded solutions. But for a successful outcome, follow the recommended checklist / task sequence given below, as all of these steps will likely need to be touched upon at some point in the process.

A. Analysis & Design Phase
1.    What is the problem to solve?  Specifically.
2.    What is one feasible solution?  Map it out.  May need to prototype it (v0) if you have limited experience with the tech involved (see step 5).
3.    What are other solutions using either no tech, or different tech?  Assess their feasibility.
4.    Cross-analyze all solution options and recommend the top two.  Explain reasoning.
B. Prototype – Iteration1
5.    Prototype solution (v1).  Document and test as you go.  Untethered power and comms can be left for later.
6.    Bench test solution.  Fix defects.  Identify essential missing features.  Streamline design and user interface (simplicity, ease of use)
7.    Prototype packaging for solution, quantity 1.  Quick and dirty is fine.
8.    Field test solution (v1.x).  Fix defects.  Identify essential missing features.  Streamline design and user interface.

C. Prototype – Iteration 2
9.    Design pre-production prototype (v2) using learnings above.
10.    Design and incorporate untethered power and comms, e.g. battery, wireless etc.
11.    Design and incorporate self-diagnostics.
12.    Design data gathering and data storage plan (no data, or write to file onboard storage and extract later, or transmit in real-time).
13.    Design pre-production packaging, considering ruggedness & penetrability (IP rating, moisture, dust, etc.).  If any cables, consider strain relief.
14.    Produce & fabricate, quantity 5.
15.    Write user instructions, inspection SOP
16.    Design trial and write-up assessment criteria.

D. Field trials
17.    Deploy for field trials.
18.    Assess trial against predefined success criteria.

E. Production Phase
19.    Design in changes from field trials.
20.    Optimize parts and build for cost.  Assess per unit production cost at scale against max build cost target.
21.    Consider build strategies and outsource options (PCB, integrated solution, FPGA, etc.)
22.    Setup and tooling costs
23.    Build minimum quantity.

F. Hygiene* (do along the way, not at the end)
24.    Documentation
25.    Open source license review
26.    Intellectual property protection (patent, copyright)
27.    Minimum KTLO (keep the lights on) requirements (maintenance, bug fixing, software repository)
28.    Plan for data storage requirements
29.    Identify maximum build cost targets for financial viability.