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Should You Outsource Manufacturing? A Handy Guide

October 24, 2016 by 46 Comments

A lot of people assume that the product development cycle involves R&D, outsourcing to a Chinese manufacturer, and then selling the finished product. It’s almost ingrained in our heads that once a prototype has been developed, the next step involves a visa and airplane tickets. Here is a guide that will explore a few other options, and why outsourcing may not be appropriate for everyone.

First, let’s talk about goals. We’ll assume you’re not a large company, and that you don’t have a huge budget, and that you’re just getting started with your product and don’t have big volumes; a startup trying to sell a kit or breakout board, or a consumer electronics product. Your goals are the following:

  1. Validate your product in the market. Build a minimum viable product and get it in the hands of lots of users
  2. Get the most bang for your limited bucks. All money should go towards getting products out the door
  3. Reduce risk to your company so that any single failure doesn’t crater the whole operation and you can safely grow.

With that in mind, what are your options?

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Toyota’s Code Didn’t Meet Standards and Might Have Led To Death

October 24, 2016 by 163 Comments

We were initially skeptical of this article by [Aleksey Statsenko] as it read a bit conspiratorially. However, he proved the rule by citing his sources and we could easily check for ourselves and reach our own conclusions. There were fatal crashes in Toyota cars due to a sudden unexpected acceleration. The court thought that the code might be to blame, two engineers spent a long time looking at the code, and it did not meet common industry standards. Past that there’s not a definite public conclusion.

[Aleksey] has a tendency to imply that normal legal proceedings and recalls for design defects are a sign of a sinister and collaborative darker undercurrent in the world. However, this article does shine a light on an actual dark undercurrent. More and more things rely on software than ever before. Now, especially for safety critical code, there are some standards. NASA has one and in the pertinent case of cars, there is the Motor Industry Software Reliability Association C Standard (MISRA C). Are these standards any good? Are they realistic? If they are, can they even be met?

When two engineers sat down, rather dramatically in a secret hotel room, they looked through Toyota’s code and found that it didn’t even come close to meeting these standards. Toyota insisted that it met their internal standards, and further that the incidents were to be blamed on user error, not the car.

So the questions remain. If they didn’t meet the standard why didn’t Toyota get VW’d out of the market? Adherence to the MIRSA C standard entirely voluntary, but should common rules to ensure code quality be made mandatory? Is it a sign that people still don’t take software seriously? What does the future look like? Either way, browsing through [Aleksey]’s article and sources puts a fresh and very real perspective on the problem. When it’s NASA’s bajillion dollar firework exploding a satellite it’s one thing, when it’s a car any of us can own it becomes very real.

WarWalking With The ESP8266

October 23, 2016 by 28 Comments

[Steve] needed a tool to diagnose and fix his friend’s and family’s WiFi. A laptop would do, but WiFi modules and tiny OLED displays are cheap now. His solution was to build a War Walker, a tiny handheld device that would listen in WiFi access points, return the signal strength, and monitor the 2.4GHz environment around him.

The War Walker didn’t appear out of a vacuum. It’s based on the WarCollar Dope Scope, a tiny, portable device consisting of an off-the-shelf Chinese OLED display, an ESP8266 module, and a PCB that can charge batteries, provide a serial port, and ties the whole thing together with jellybean glue. The Dope Scope is a capable device, but it’s marketed towards the 1337 utilikilt-wearing, The Prodigy-blasting pentesters of the world. It is, therefore, a ripoff. [Steve] can build his version for $6 in materials.

The core of the build is an ESP-based carrier board built for NodeMCU. This board is available for $3.77 in quantity one, with free shipping. A $2 SPI OLED display is the user interface, and the rest of the circuit is just some perfboard and a few wires.

The software is based on platformio, and dumps all the WiFi info you could want over the serial port or displays it right on the OLED. It’s a brilliantly simple device for War Walking, and the addition of a small LiPo makes this a much better value than the same circuit with a larger pricetag.

Impressive Pi System Controls Large Office

October 22, 2016 by 37 Comments

A pile of Raspberry Pis isn’t what would spring to mind for most people when building a system to control a large office, but most people aren’t [Kamil Górski]. He decided to use Pis to run the office of his company Monterail when they moved to a larger space. The system they built is one of the largest Pi installations we have seen, controlling the lights, TVs, speakers and door access. It can all be controlled through a web interface, so anyone on the network can turn the lights on or off, check if a room is occupied or send sound and video to the fancy AV system in the conference room. He even hacked a bunch of HDMI switches so that every TV can show the same image if everyone wants to watch the same event. Even the radio station that plays in the lounge is controlled remotely from an employee slack channel.

The system is run on five Pis, one of which acts as a master, while the others are connected to each of the TVs, running Chrome in console mode being remotely controlled through the Chrome Debugging Protocol.  That allows anyone on the network to control the display and send content to it. One interesting thing to note: [Kamil] freely admits that this is a bespoke system that couldn’t be easily sold as a product. Nothing wrong with that, but he decided to build in some backups: if the whole system fails, all of the lights, doors, and other devices can still be controlled through old-school switches, keys, and remote controls. Even a full system crash doesn’t render the office unusable. That’s a wide precaution that many people forget in systems like this.

You Might Not Be Able To Read This

October 21, 2016 by 110 Comments

Early today, some party unleashed a massive DDoS attack against Dyn, a major DNS host. This led to a number of websites being completely inaccessible. DNS is the backbone of the Internet. It is the phone book that turns URLs into IP addresses. Without it, the Internet still works, but you won’t be able to find anything.

Over the past few months, security professionals have suggested — in as responsible terms as possible — that something big could happen. In early September [Bruce Schneier] wrote, Someone Is Learning How To Take Down The Internet. The implication of this very general warning is that someone — possibly a state actor, but don’t be too sure about that — was figuring out how to attack one of the core services of the web. The easiest way to effectively ‘turn off the Internet’ for everyone is a Distributed Denial of Service attack against root servers, DNS servers, or some other service that plays a key role in the web.

Dyn is responding well to the attack this morning, and the Internet is safe from attack for the time being. As for who is responsible for the attack, what the goal is, and if this will happen again, no one knows. An attack on this scale is most certainly someone with a very large pocketbook or a state actor (Russia, China, the US, UK, Germany, Israel, or the like) but that’s not a given. It’s also not given the DDoS attacks have stopped. You might not be able to read this, but if you can, it might be a good idea to find a shortwave radio.

Hajime, Yet Another IoT Botnet

October 20, 2016 by 30 Comments

Following on the heels of Mirai, a family of malware exploiting Internet of Things devices, [Sam Edwards] and [Ioannis Profetis] of Rapidity Networks have discovered a malicious Internet worm dubbed Hajime which targets Internet of Things devices.

Around the beginning of October, news of an IoT botnet came forward, turning IP webcams around the world into a DDoS machine. Rapidity Networks took an interest in this worm, and set out a few honeypots in the hopes of discovering what makes it tick.

Looking closely at the data, there was evidence of a second botnet that was significantly more sophisticated. Right now, they’re calling this worm Hajime.

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Are Today’s Engineers Worse?

October 20, 2016 by 142 Comments

Today’s engineers are just as good as the ones that came before, but that should not be the case and there is massive room for improvement. Improvement that can be realized by looking for the best of the world to come and the one we left behind.

Hey kids! Let's learn why the CE certifications exist!
Hey kids! Let’s learn why the CE certifications exist!

Survivorship bias is real. When we look at the accomplishments of the engineers that came before us we are forced to only look at the best examples. It first really occurred to me that this was real when I saw what I still consider to be the most atrocious piece of consumer oriented engineering the world has yet seen: the Campbell’s soup warmer.

This soup warmer is a poor combination of aluminum and Bakelite forged into the lowest tier of value engineering during its age. Yet it comes from the same time that put us on the moon: we still remember and celebrate Apollo. It’s possible that the soup warmer is forgotten because those who owned it perished from home fires, electrocution, or a diet of Campbell’s soup, but it’s likely that it just wasn’t worth remembering. It was bad engineering.

In fact, there’s mountains of objects. Coffee pots whose handles fell off. Switches that burned or shocked us. Cars that were ugly and barely worked. Literal mountains of pure refuse that never should have seen the light of day. Now we are here.

The world of engineering has changed. My girlfriend and I once snuck into an old factory in Louisville, Kentucky. The place was a foundry and the only building that survived the fire that ended the business. It happened to be where they stored their professional correspondence and sand casting patterns. It was moldy, dangerous, and a little frightening but I saw something amazing when we cracked open one of the file cabinets. It was folders and folders of all the communication that went into a single product. It was an old enough factory that some of it was before the widespread adoption of telephony and all documents had to be mailed from place to place.

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