Background#

As part of the sales and early engagement process, customers typically provide a Customer Requirements Specification (CRS). The format, level of detail, and quality of this CRS can vary significantly depending on the customer's experience, organization size, and maturity of their product development processes. In practice, a CRS may range from a structured and formal specification to informal materials such as presentations, meeting notes, sketches, or even a brief conceptual description. While such input is valuable, it often introduces several risks when used directly as the basis for estimation – or quotation – and development.

Common challenges with customer-provided requirements#

Functionality versus implementation#

To stimulate innovation and arrive at optimal solutions, requirements should initially describe what the product must do from an end‑user and system perspective, rather than how it should be implemented. Premature focus on technical solutions can unnecessarily constrain design freedom and obscure opportunities for innovation. In practice, customers often mix functional intent with implementation choices. While this may sometimes be justified (e.g. platform reuse or legacy compatibility), it requires careful analysis to avoid suboptimal or overly constrained designs.

Testability and verification#

A frequent omission in early requirements is the definition of how compliance will be demonstrated. Each requirement must be verifiable, meaning that clear acceptance criteria and test methods are defined. For high‑performance systems, verification may require dedicated test equipment, fixtures, software tooling, or environmental setups. Failure to identify this early introduces significant project risk.

Completeness and context#

Customer requirements often contain implicit assumptions that are obvious to the customer but not documented. Additionally, edge cases such as fault handling, abnormal operation, or integration with external systems are frequently under‑specified. Without explicitly capturing the broader operational and business context, critical requirements may remain hidden until late in the project.

Reliable project estimation#

Incomplete or ambiguous requirements make reliable estimation of cost, effort, and lead time extremely difficult. This often results in either excessive contingency (leading to unattractive offers) or underestimated effort (leading to delays and dissatisfaction). In practice, the effort required to clarify requirements must be invested at some point; performing this work early enables making better decisions for all parties involved.

These guidelines describe a structured, phased approach that addresses these challenges by progressively refining requirements and using them as a solid foundation for estimation and development planning.

Objectives#

The objectives of this approach are twofold:

  • Actively help customers increase the quality, feasibility, and innovativeness of their product concepts.
  • Enable the creation of reliable, transparent, and defensible project estimations in terms of scope, schedule, budget, and risk.

To achieve this, requirements are:

  • Structured from user‑centric product requirements to technical system requirements.
  • Explicitly verified for completeness, consistency, and testability.
  • Agreed upon by all relevant stakeholders.
  • Used as the basis for phased estimation and development planning.

Overall Approach#

After receiving the CRS, we apply a phased refinement process:

  1. Product Requirements Analysis
    Transform the CRS into a structured Product Requirements Specification (PRS).

  2. System Requirements Analysis
    Translate product requirements into a System Requirements Specification (SRS) and validate feasibility and identify any risks.

  3. Industrialisation Requirements Analysis (if applicable)
    Capture requirements related to volume production, quality, and supply chain, resulting in an NPI specification.

  4. Product Development Planning and Estimation
    Use the validated requirements to construct a well‑founded development plan and project estimation.

Each phase produces concrete deliverables and clear decision points and is explicitly positioned as part of the sales and early engagement process.

Each phase can be offered and executed as a separate, short‑term project that can be purchased independently.

After completion of a phase, the customer may decide whether to continue with the next phase, use the results internally, or engage other partners.

This phased, modular approach reduces risk and uncertainty while allowing informed, step‑by‑step investment and go/no‑go decisions as the project progresses.

Phase deliverables at a glance#

Each phase concludes with a defined set of deliverables that form the input to the next phase and the basis for the customer's go/no‑go decision. The table below summarises the primary and supporting deliverables per phase; the detailed lists are repeated at the end of each phase description and in the corresponding full guidelines.

PhaseAnalysis focusPrimary deliverableSupporting deliverables
Phase 1 Product Requirements Analysis Product Requirements Specification (PRS) System identification model and context diagram; use case model with scenarios and dependency map; system state model; functional and non‑functional requirements lists; prioritised and traceable requirements with acceptance criteria
Phase 2 System Requirements Analysis System Requirements Specification (SRS) System architecture definition; concept analysis and trade‑off selection; proof‑of‑concept prototypes (if applicable); Design Risk Evaluation; initial Bill of Materials and product pricing indication; initial Product Test Plan; refined/adjusted PRS
Phase 3 Industrialisation Requirements Analysis (if applicable) New Product Introduction (NPI) specification Production requirements agreement; manufacturing concept analysis; EMS partner evaluation and selection; initial supply‑chain strategy and key‑component risk assessment
Phase 4 Product Development Planning and Estimation Product Development Plan Development phases, milestones and decision gates; resource and competency plan; effort, cost and schedule estimation; risk mitigation plan; EMS/supplier alignment (if applicable)

Phase 1Product Requirements Analysis#

Open the full Phase 1 guidelines

Purpose#

The purpose of the Product Requirements Analysis phase is to clearly define what the product shall do and how it shall behave from an end‑user and stakeholder perspective, without prescribing technical solutions unless strictly necessary.

This phase is typically executed as a joint effort between the customer's product management and the system engineering team. Methods such as workshops, interviews, scenario‑based design, and early mock‑ups or prototypes may be used to validate understanding and gather feedback.

The primary deliverable is the Product Requirements Specification (PRS).

System identification#

To manage complexity, the product is first positioned within its operational context.

  • Define the main product objective
    Clearly state the primary purpose and value proposition of the product.
  • Define the product context
    Describe the environment, users, external systems, and constraints, forming the product ecosystem.
  • Identify system actors
    Identify all actors (users, external systems, devices) and their roles.
  • Identify product elements
    Determine which actors correspond to devices or subsystems that are within the project scope.
  • Identify external interfaces
    Define key interfaces (physical and logical) the product has with the outside world.
  • Identify all artifacts
    Identify all artifacts—non-behavioral data objects or physical items (e.g., files, messages, tokens)—that cross the system boundary as inputs, outputs, or bidirectional exchanges.

Functional requirements#

Based on the system identification, functional requirements are defined using use cases and scenarios.

  • Define use cases
    Each use case represents a user or system objective and identifies the involved actors.
  • Define scenarios per use case
    Scenarios describe normal operation, alternative flows, and failure conditions, including preconditions, sequences, and postconditions. These descriptions already serve as high‑level acceptance criteria.
  • Define dependencies and interactions
    Dependencies between use cases are mapped to support planning and prioritisation.

Non‑functional requirements#

Requirements not directly tied to specific use cases are captured as non‑functional requirements, such as:

  • Regulatory and compliance requirements
  • Performance, reliability, and safety constraints
  • Localization, markets, and environmental conditions
  • Business or branding constraints

Prioritisation#

Use cases and scenarios are prioritized based on business value, risk, dependencies, and technical complexity. This prioritization directly supports phased development, MVP definition, and release planning.

Deliverables#

  • Product Requirements Specification (PRS) — the primary deliverable, consolidating all of the work products below into a single solution‑neutral specification.
  • Business case background and product/market context.
  • System identification model: main product objective, product context, system actors, product elements in scope, external interfaces, artifacts, and a context diagram.
  • Use case model: use cases, use case dependency diagram, and use case scenarios (normal, alternative, and failure flows).
  • System state model (state table, transition table, and state diagram).
  • Functional requirements list, extracted from the scenarios.
  • Non‑functional requirements list (regulatory, performance, environmental, business/branding constraints).
  • Prioritised requirements with acceptance criteria and a requirements list with traceability.

Phase 2System Requirements Analysis#

Open the full Phase 2 guidelines

Purpose#

The System Requirements Analysis phase translates product requirements into technical system requirements and evaluates feasibility, risks, and design implications from a multidisciplinary perspective. As a result the PRS might be refined or adjusted based on technical insights.

Key deliverables include:

  • System architecture definition
  • Conceptual prototypes or proof‑of‑concepts if applicable
  • System Requirements Specification (SRS)
  • Initial Product Test Plan

System architecture#

A high‑level system architecture is defined by functionally decomposing the product requirements into subsystems and components. This architecture provides:

  • A shared technical vision
  • A basis for work breakdown and responsibility allocation
  • Input for risk assessment and planning

Concept analysis#

For each major subsystem, implementation concepts are evaluated:

  • Trivial concepts – Only one reasonable solution exists.
  • Balanced concepts – Multiple viable solutions require trade‑off analysis.
  • Exploratory concepts – Feasibility is uncertain and must be proven.

Prototyping and feasibility validation#

Where uncertainty exists, targeted prototyping is performed to validate critical design aspects, performance limits, or manufacturing processes. Prototypes may range from quick experiments to more elaborate demonstrators. Results are reviewed with the customer and used to finalise architectural and requirement decisions.

Design Risk Evaluation#

A structured design risk analysis that validates the robustness of the proposed architecture and ensures that identified failure modes are either mitigated through requirements, architectural safeguards, or explicitly accepted.

System Requirements Specification#

All validated technical requirements, constraints, and interfaces are documented in the System Requirements Specification (SRS). Requirements are written to be unambiguous, traceable, and verifiable.

Initial product pricing#

Based on the system architecture and preliminary component selection, an initial bill of materials (BoM) is created to provide an early indication of production cost and pricing sensitivity.

Initial Product Test Plan#

A first version of the Product Test Plan is created, describing verification strategies, required test equipment, and acceptance criteria for product and system requirements.

Deliverables#

  • System Requirements Specification (SRS) — the primary deliverable, capturing all validated technical requirements, constraints, and interfaces in an unambiguous, traceable, and verifiable form.
  • System architecture definition (functional decomposition into subsystems and components).
  • Concept analysis with trade‑off evaluation and concept selection per major subsystem.
  • Conceptual prototypes or proof‑of‑concepts, where feasibility is uncertain (if applicable).
  • Design Risk Evaluation documenting failure modes and their mitigation or acceptance.
  • Initial Bill of Materials (BoM) and an early product cost/pricing indication.
  • Initial Product Test Plan.
  • Refined or adjusted PRS, where technical insights require changes to product requirements.

Phase 3Industrialisation Requirements Analysis#

Open the full Phase 3 guidelines

Purpose#

When a product is intended for volume production, additional requirements related to manufacturability, quality, and supply chain must be addressed early to avoid costly redesigns.

The primary deliverable of this phase is a New Product Introduction (NPI) specification.

Production requirements agreement#

Together with the customer, high‑level agreements are established on:

  • Quality and reliability targets
  • Production volumes and ramp‑up expectations
  • Service, support, and lifecycle considerations

Manufacturing concept analysis#

Preliminary manufacturing concepts are developed and assessed, including:

  • Validation of critical manufacturing processes
  • Production and end‑of‑line test strategies
  • Assembly, calibration, and packaging methods

EMS partner selection#

Based on product characteristics, quality requirements, and volume expectations, suitable EMS partners are evaluated and selected.

Supply chain considerations#

Key components and supply risks are identified, and an initial supply chain strategy is defined to mitigate availability, lead‑time, and obsolescence risks.

Deliverables#

  • New Product Introduction (NPI) specification — the primary deliverable, consolidating the industrialisation requirements below.
  • Production requirements agreement: quality and reliability targets, production volumes and ramp‑up expectations, and service/support/lifecycle considerations.
  • Manufacturing concept analysis: validation of critical processes, production and end‑of‑line test strategies, and assembly, calibration, and packaging methods.
  • EMS partner evaluation and selection.
  • Initial supply‑chain strategy with key‑component and supply‑risk assessment.

Phase 4Product Development Planning and Estimation#

Open the full Phase 4 guidelines

Purpose#

In this final pre‑development phase, the outputs of all previous phases are consolidated into a concrete development plan and project estimation.

Activities#

In close cooperation with all stakeholders, the following activities are performed:

  • Definition of development phases, milestones, and decision gates
  • Resource and competency planning
  • Alignment with EMS partners and suppliers (if applicable)
  • Detailed effort, cost, and schedule estimation
  • Definition of risk mitigation actions
  • Construction and review of the Product Development Plan

The resulting plan and estimation are reviewed with the customer and form the basis for contractual agreements and project execution.

Deliverables#

  • Product Development Plan — the primary deliverable, consolidating the outputs of all previous phases into an executable plan.
  • Definition of development phases, milestones, and decision gates.
  • Resource and competency plan.
  • Detailed effort, cost, and schedule estimation.
  • Risk mitigation plan.
  • EMS partner and supplier alignment (if applicable).

1.Introduction#

1.1.Purpose and Context#

A Product Requirements Specification (PRS) is a comprehensive document whose objective is to clearly define what a product must do and how it should behave from an end-user and stakeholder perspective. It captures the product's intended functions, features, and constraints without prescribing a specific technical solution, ensuring the focus remains on what the product needs to achieve rather than how it will be implemented. This means that design decisions are deliberately excluded.

The PRS plays a critical role in product development as the contractual baseline of requirements: it is the agreement on "what the product must do". Decisions on design and implementation (the how) are addressed in later phases.

In a high-tech electronics context (hardware and embedded software), a well-crafted PRS provides a clear target for engineers and stakeholders, aligning everyone on the product goals and serving as the reference point for design, implementation, and verification.

The PRS is the primary output of the Product Requirements Analysis phase – the first pre-development phase of a structured product development process.

For context, the pre-development phases are:

  1. Product Requirements Analysis
    Defines what the product shall do and how it shall behave from an end-user and stakeholder perspective, without prescribing technical solutions unless strictly necessary.

  2. System Requirements Analysis
    Performs the technical translation of the product requirements and, where required, implements proof-of-principle (PoP) prototypes for the whole product or for specific functional components. This phase also evaluates the feasibility of each product requirement and feeds adjustments back to the PRS where needed.

  3. Industrialisation Analysis
    An optional phase required only when a product is intended for volume production with a required level of quality. In that case, additional requirements related to manufacturability, quality, and supply chain are addressed early to avoid costly redesigns.

  4. Product Development Planning
    Using the outputs of all previous phases, a detailed plan is constructed to develop and produce the product, estimating the required budget and timeframe, including resource allocations and supply chain.

The main objective of the pre-development phases is to arrive at a solid product development plan that steers the subsequent activities for hardware, software, and (where required) mechanical development.

1.2.Deliverables#

The PRA phase produces a single, consolidated deliverable:

  • Product Requirements Specification (PRS)
    A comprehensive, solution-neutral document that defines what the product must do and how it must behave from an end-user and stakeholder perspective. It is the contractual baseline of requirements and the reference against which design proposals are evaluated and verification is planned.

Unlike the later phases, which emit several distinct artifacts, the PRA consolidates all of its work products into the chapters of this one document. The PRS contains:

  • Business Case Background
    The product intent, market context, and commercial assumptions that motivate and bound the requirements.
  • System Identification
    The main product objective, product context, system actors, product elements in scope, external interfaces, artifacts, and a context diagram.
  • Use Cases
    The use cases with their actors and interactions, the use case dependencies, and a use case dependency diagram.
  • System State Model
    The state table, choice-point and transition tables, and state diagram describing the product's modes of operation.
  • Use Case Scenarios
    Normal, alternative, and failure flows per use case, including preconditions and postconditions, which serve as high-level acceptance criteria.
  • Functional Requirements
    The functional requirements extracted from the scenarios, traceable to their originating steps.
  • Non-Functional Requirements
    Requirements not tied to a specific use case, such as regulatory, performance, reliability, environmental, and business or branding constraints.
  • Prioritisation
    Priority levels assigned to requirements and use cases, with a dependency-consistency check, supporting MVP definition and release planning.
  • Acceptance Criteria and Verifiability
    Clear, verifiable acceptance criteria integrated with the requirements.
  • Requirements Listing and Traceability
    A consolidated requirements list with traceability back to its sources.

2.Overview#

The Product Requirements Analysis phase is dedicated to defining the product's requirements in detail, laying the groundwork for all design and development efforts.

The primary purpose of this phase is to determine what the product shall do and how it shall behave from the perspective of end-users and other stakeholders. This involves gathering and analysing inputs such as user needs, business objectives, and high-level use scenarios, and systematically formulating requirements without diving into technical implementation. The culmination of this phase is the Product Requirements Specification (PRS), which formally captures all identified requirements.

During the phase, the system engineering (SE) team performs a structured series of steps to ensure no aspect of the product's required behaviour is overlooked:

  1. The business case background is captured to frame the product's market context.
  2. The product is positioned within its intended system context and environment.
  3. Use cases are identified by specifying the key objectives and interactions the product must support.
  4. The system's operational behaviour is modelled through states and transitions.
  5. For each use case, scenarios are authored illustrating how the system behaves in normal conditions as well as in alternative and failure conditions.
  6. Functional requirements are extracted from the scenarios as explicit "shall" statements.
  7. Non-functional requirements are captured (performance, reliability, compliance, environmental, and so on).
  8. Requirements are prioritized based on stakeholder value, risk, and dependencies.
  9. Acceptance criteria are defined to ensure each requirement is verifiable.
  10. All requirements are compiled and traced in the PRS, and supporting information (glossary, references, appendices) is included for completeness.

It is crucial to distinguish Product Requirements Analysis from subsequent pre-development phases. In this phase, the focus is purely on what the product needs to do, i.e. product-level requirements that reflect user needs and business goals, independent of any particular technical solution. The subsequent System Requirements Analysis phase takes the PRS as input and determines how to implement those requirements in terms of architecture, components, and technologies. By keeping the PRS solution-neutral, the SE team avoids prematurely constraining the design and preserves the flexibility to explore multiple implementation options. The PRS thus becomes a stable reference that is used to validate the final product: a clear contract of what the product must do, against which design proposals can be evaluated and testing can be planned.

A direct consequence of this separation is that the PRS is feasibility-unconstrained by design. It states what the product must do; whether each requirement is achievable – and at what cost – is evaluated during System Requirements Analysis (SRA), not asserted in the PRS. The results of that evaluation (often expressed through an initial bill-of-materials cost) are reviewed with the customer and may feed back into an adjusted PRS. This feedback loop is intended and may occur several times. The implications for how values are stated and flagged are developed below in section 2.2.

2.1.Solution Neutrality#

Solution neutrality is central to everything that follows.

The PRS defines what the product must do and how it must behave from an end-user and stakeholder perspective. It must never prescribe internal implementation details. This applies to every part of the document: use cases, scenarios, states, requirements, and acceptance criteria.

Keeping the PRS solution-neutral preserves design freedom, enables innovation, and allows the engineering team to explore multiple implementation options during the later System Requirements Analysis phase. Premature implementation choices in the PRS risk constraining the design unnecessarily or hiding the actual functional need behind a specific technology.

Not all technical terms are implementation details, however. Some technologies are chosen at the product level because they define the user experience, market positioning, or ecosystem compatibility. These are legitimate product requirements. The distinction is:

  • Product-level technology choices are visible to the user or driven by business or market needs. They describe what capability the product offers. Examples: "The system shall support Wi-Fi connectivity"; "The system shall provide a capacitive touchscreen interface"; "The system shall support Bluetooth audio streaming". These belong in the PRS.
  • Implementation details describe how the product achieves specific capabilities internally. Examples: "using an SPI bus", "with an STM32 microcontroller", "firmware shall use a state machine", "data stored in flash memory". These do not belong in the PRS.

A useful rule of thumb: if the user or customer can see, interact with, or would care about the technology choice, it is a product-level decision and belongs in the PRS. If it is only relevant to the engineering team building the product, it is an implementation detail and belongs in later phases.

Customer input often mixes functional intent with implementation preferences. When this occurs, extract the underlying functional need as a requirement. If the implementation choice is a product-level technology decision, include it as stated. If it is an internal implementation detail, omit it from the requirement and – only if the customer explicitly insists on it – note it as a constraint with documented rationale. For example:

  • Customer input: "Use Wi-Fi for service connection." → Product-level choice. Requirement: "The system shall provide a Wi-Fi-based wireless connection for service access."
  • Customer input: "Use an STM32 microcontroller." → Implementation detail. Do not include it as a requirement. If explicitly mandated, note it as a constraint: "The customer has specified the use of an STM32 microcontroller [TBC]."

2.2.Handling Unknown Values#

A PRS inevitably contains values that are not yet pinned down: target volumes, response-time limits, environmental ranges, certification scopes, power budgets. The temptation is to mark every such value with a flag and move on. That is a mistake, and it produces documents cluttered with dozens of pending items, most of which are not genuinely open. Before flagging any value, the systems engineer must ask one question: who is the authority for this value? The answer determines whether the value is flagged, stated with a citation, or simply expressed as a need and left to a later phase.

Two markers are used throughout the PRS:

  • [TBD] (To Be Determined) – a required value that is genuinely not yet determined and must be resolved before the PRS is baselined. Used only where the authority for the value is the customer/stakeholder or established knowledge, and the value is simply missing.
  • [TBC] (To Be Confirmed) – a value that is present but requires confirmation from stakeholders. Used only where a stakeholder is the authority for the value.

Before attaching either marker, apply the authority test:

  • A stakeholder is the authority. Target volume, certification regions, expected service life, a customer-owned behavioural choice – only the customer or another stakeholder can supply these. Flag with [TBC] if a value is stated and needs confirmation, or [TBD] if it is genuinely missing. These are the proper subject of the Pre-Draft Triage in section 3.2.
  • Published standards, established science, or domain knowledge is the authority. Some values are not unknown at all, but are fixed by a cited standard or by well-established knowledge. A common example is the human-perception ceiling for "instantaneous" feedback (around 100 ms), established in the human–computer-interaction literature. Such a value is not flagged; it is stated firmly, and the rationale names the source. A reviewer checks the citation, not their own preference.
  • The engineering team is the authority. Many quantitative values – achievable power consumption, a concrete mounting specification, an internal timing budget – are design or feasibility outputs. Their concrete value is not knowable at the PRS stage and is not a stakeholder decision. Do not flag these as pending items. Instead, state the functional need (e.g., "the unit shall be mountable by one person without specialist tooling") and let the System Requirements Analysis phase determine the concrete figure.

A reflex worth unlearning is attaching [TBC] to a number simply because it is a number, or because its achievability has not been confirmed. If the number is settled by established knowledge, cite it and leave it unflagged. If its achievability is the open question, that is a feasibility matter – and feasibility, as the following note explains, is out of scope for the PRS.

Feasibility is out of PRS scope. The PRS states what the product must do and is feasibility-unconstrained by design. The feasibility of every requirement – and its cost – is evaluated during System Requirements Analysis (SRA), whose results (often expressed through an initial bill-of-materials cost) are reviewed with the customer and may feed back into an adjusted PRS. This feedback loop is intended and may occur several times. Consequently, no requirement in the PRS carries a feasibility caveat or annotation, and no value is flagged [TBD]/[TBC] merely because its achievability is unconfirmed. Achievability is not a PRS question.

3.Customer Requirements Elicitation Methods#

Developing a strong PRS requires effective gathering of input from all relevant stakeholders. The initial input for the PRS is the Customer Requirements Specification (CRS), and during the Product Requirements Analysis, systems engineers collaborate closely with the customer's product managers, end-users (where available), and business stakeholders to extract a complete and validated set of requirements.

3.1.Practical Methods#

Practical methods to obtain customer requirements can be one or more of the following:

  • Stakeholder interviews
    Structured interviews with product managers, end-users, clients, and domain experts to capture their needs, expectations, and pain points. Open-ended questions help uncover implicit requirements and clarify the desired product behaviour in various scenarios.
  • Workshops and brainstorming sessions
    Cross-functional discussions (marketing, engineering, customer representatives, and so on) that enable real-time clarification, prioritize conflicting needs, and build consensus. Visual aids such as mind maps or whiteboarding help define the product context and features.
  • Scenario-based design and use case development
    Scenario planning to envision how the product will be used in real-world situations. Writing narratives or storyboards that walk through typical user interactions – as well as edge cases – ensures requirements are rooted in actual user workflows and helps identify missing interactions or abnormal situations.
  • Early mockups or prototypes
    Simple mockups, sketches, or low-fidelity prototypes reviewed with stakeholders to validate understanding. Seeing a model or simulation often elicits additional requirements or corrections, particularly for user-interface-intensive products. For hardware products, this may involve concept drawings or basic lab experiments to confirm feasibility of performance targets.
  • Surveys and questionnaires
    Where direct access to many end-users is possible, surveys can gather quantifiable data on user needs and preferences. Useful for capturing user-centred requirements at scale or for prioritizing features.

Key discussions and confirmations from these workshops and interviews are documented, whether as meeting minutes or a requirements backlog. These notes ensure nothing is lost and provide justification for requirements in the PRS.

3.2.Pre-Draft Triage of Customer-Authority Gaps#

Some facts can only come from the customer – no amount of engineering judgement, published standard, or domain knowledge can recover them. These are predominantly the Business Case Background facts (target volume, rollout profile, expected service life, cost positioning, certification regions, customer identity) and any genuinely customer-owned behavioural choices the input leaves open.

It is good practice to surface these as a short, focused triage round before drafting the body of the PRS, rather than discovering them as scattered flags afterwards. Stakeholders answer such questions far better when asked directly and early, against a concrete list, than when confronted with a draft full of markers. For each question, the customer can:

  • Answer – the value is used directly, with no flag.
  • Skip for now – the question is left open; the engineer proceeds with a best-inferred value, marks it [TBC] (inferred) or [TBD] (genuinely missing), and the item is consolidated for later resolution.
  • Skip the remainder – the round ends; all remaining gaps are handled by drafting with judgement and flagging.

The triage round is an aid, never a gate: if the customer declines to engage or simply asks for a draft, the PRS is still produced, with judgement applied and gaps flagged. There is no fixed limit on the number of triage questions; if the input genuinely leaves many customer-authority facts open, asking all of them is appropriate.

Crucially, triage is only for facts whose authority is the customer or another stakeholder (see section 2.2). It must not be used to ask the customer for values the engineering team or published knowledge is the authority for. Latency budgets, power consumption, reliability figures, environmental ranges, mounting specifications, and similar engineering values are resolved later by the authority test and by System Requirements Analysis – not by the customer. Asking the customer to sign off on such a number routes the decision to the party least equipped to make it.

3.3.Output#

The elicitation methods help ensure the PRS is user- and business-centred. They turn the often vague initial input – which may be a solid Customer Requirements Specification or just a concept description – into concrete, structured requirements.

During elicitation, the focus must be on uncovering the why behind each requirement: what value or outcome it is tied to. This context is critical later when prioritizing requirements and making design trade-offs. It is equally important to document assumptions or implicit needs that surface. Throughout, close collaboration with the client and end-users is maintained; the PRS should ultimately reflect a shared understanding of the product goals.

4.Business Case Background#

4.1.Purpose#

The purpose of including a "Business Case Background" chapter in the PRS is to provide high-level business context for the product. While the PRS formally defines what the product shall do and how it shall behave, the Business Case Background describes the market problem the product addresses and explains the commercial and strategic setting in which the product is developed.

This context ensures that the product requirements – and especially the Main Product Objective defined in the System Identification chapter – are interpreted correctly and remain aligned with the intended market positioning. This chapter does not contain requirements and does not replace the customer's business case documentation; it provides only sufficient background to frame the remainder of the PRS.

4.2.Product Intent and Market Context#

The first section in the "Business Case Background" chapter briefly describes:

  • The market problem the product addresses.
  • The intended customer or user segment.
  • The high-level positioning of the product (performance-focused, cost-optimized, specialized niche solution, and so on).

The description should be concise and factual, providing only the information necessary to understand the product's intended purpose and differentiation.

Commercial Assumptions#

To properly interpret requirements and prioritization decisions, a limited number of business assumptions should be documented where available:

  • Target production volume (order of magnitude).
  • Expected product lifetime in the market.
  • Cost positioning strategy (aggressive unit-cost target versus premium solution).
  • Planned certification regions or regulatory scope.

These assumptions influence architectural decisions, prioritization, and feasibility assessments in later phases. Documenting them here provides transparency and supports consistent decision-making. Where information is unavailable or uncertain, apply the authority test (section 2.2): these facts are almost all customer/stakeholder-authority, so a stated-but-unconfirmed value is marked [TBC] and a genuinely missing value is marked [TBD]. Because they are customer-owned, these are exactly the facts the Pre-Draft Triage (section 3.2) should surface as questions; where the customer has answered, the value is used with no flag.

4.3.Role in the PRS#

The Business Case Background provides context, not constraints. It enables:

  • A more precise definition of the Main Product Objective.
  • Clearer prioritization of use cases and scenarios.
  • Better alignment between product requirements and business intent.
  • More informed trade-off discussions during System Requirements Analysis.

All detailed product behaviour and constraints are defined in the subsequent chapters of the PRS.

5.System Identification#

After the business case is formulated to serve as background and context, the first step in building the body of the PRS is System Identification, where the product is defined in the context of its intended environment and usage. The goal is to position the product within its operational context and clarify its boundaries and interactions before detailed requirements are written. This step helps manage complexity by grounding the requirements in real-world context and ensuring a common understanding of the system's scope.

5.1.Main Product Objective#

The first step in the system identification is clearly stating the primary purpose of the product and its core value proposition in one or two sentences. This is done by describing the fundamental need or problem the product addresses. This high-level objective anchors all further requirements. For example: "to continuously monitor and report environmental conditions in an industrial plant".

5.2.Product Context#

The next step is to describe the environment in which the product will operate and the external entities it will interact with. This includes the typical users or operators, external systems, devices, or networks, as well as any physical or regulatory environment constraints. In short, outline the product ecosystem. Defining context ensures that requirements align with real operational conditions.

5.3.System Actors#

It is important to list all actors that interact with the product. Actors may be human users (end-users, administrators, maintenance personnel) or external systems and devices (sensors, external software services, hardware modules). The system itself is always part of every use case and is not listed as an actor.

Actors are organised into separate subsections by type: Human Actors and External Systems. Each list contains the columns Actor, Description, and Primary Objectives.

Generalized Actors#

When multiple specific actors perform the same interaction with the system – for example, when an Engineer, a Technician, and a Manager all establish a wireless service connection – a generalized actor is defined that represents the shared role (e.g., "Service User"). The generalized actor is listed in the appropriate table and it is documented which specific actors can fulfil that role. Use cases and scenarios can then reference the generalized actor, avoiding duplication of identical interactions. Differences between the specific actors (such as access level, available functionality, or operational context) are captured through specific requirements where relevant, not through separate use cases or scenarios for each actor.

5.4.Product Elements in Scope#

When developing a new product, it is essential to determine which parts of the overall context are within the project's scope to develop or deliver. In other words, it is important to distinguish between the product itself and external systems. Some actors or subsystems may be outside the development scope, whereas others are product elements to be developed. Clarifying this boundary ensures the PRS focuses only on requirements for the product under development and references external interfaces or assumptions for everything outside it.

5.5.External Interfaces#

No product operates in isolation and therefore it is beneficial to explicitly enumerate all interfaces the product has with the outside world. Interfaces are described in terms of their functional purpose and externally observable characteristics – what the interface connects to and what it is used for. These descriptions do not enumerate individual pin assignments, signal lists, register maps, or protocol field definitions. Detailed interface specifications belong in later phases.

To distinguish interfaces from regular text practically, all interfaces are named using Title Case (e.g., "Touch Display", "Charging Port", "Service Web Interface").

Interfaces are then organized into subsections by type, each using a table with columns: Interface, Direction (In/Out/Bidirectional), and Description. Typical types include, but are not limited to:

  • Physical Interfaces
    Tangible connections such as connectors, buttons, and network ports.
  • Logical Interfaces
    Communication protocols, data formats, and software-level connections.

Depending on the product, additional types may be added (e.g., "Wireless Interfaces", "Mechanical Interfaces", "Optical Interfaces").

5.6.System Artifacts#

Explicitly identifying all artifacts that cross the system boundary during operation make it possible to create a clear domain model. Artifacts are discrete data objects or physical items exchanged between the system and external actors. Unlike actors, artifacts do not initiate behaviour; they are non-behavioural objects involved in interactions. They may be inputs to the system, outputs generated by the system, or exchanged bidirectionally.

Artifacts are described in terms of their functional role and externally observable characteristics – what kind of thing the artifact is and what purpose it serves. These descriptions do not enumerate the concrete contents, parameter lists, field names, or internal structure. For example, for a "Operational Parameters" artifact, describe it as "Configurable values controlling the operational behaviour of the system, such as session timing, operating mode, and feature toggles" – not as a full list of every parameter. Concrete details belong elsewhere: individual parameters become functional requirements, and any consolidated reference list can go in an appendix.

To distinguish artifacts from regular text practically, all artifacts are named using Title Case (e.g., "Configuration Parameters", "Firmware Package", "Access Token").

Artifacts are then organized into subsections by type, each using a table with columns: Artifact, Direction (In/Out/Bidirectional), and Description. Typical types include, but are not limited to:

  • Data Artifacts
    Data objects such as configuration files, log exports, communication payloads, and user-interface artifacts such as screens, windows, pages, or dialogs that the system generates and presents to users. UI artifacts are distinct from the interface on which they are presented: the Touch Display is an interface, but each window shown on it (e.g., "Standby Window", "Session Preparation Window", "Authentication Page") is an artifact – a discrete object that the system generates and the user perceives through the interface. List each window, screen, or page by name with a brief functional description; detailed layouts and contents belong in functional requirements or an appendix.
  • Physical Artifacts
    Physical items such as keys, cards, tokens, and coins.

Depending on the product and technology, additional types may be added (e.g., "Electrical Artifacts", "Optical Artifacts").

5.7.Context Diagram#

The final step is to include a context diagram showing the product, its actors, its interfaces, and the artifacts that cross the system boundary. The context diagram is a visual summary of the information captured in the preceding subsections and gives readers an at-a-glance understanding of the product's operational setting.

5.8.Result#

By thoroughly documenting the system identification, the PRS sets the stage for all subsequent requirements. It provides a shared understanding of the context in which the product will function. All functional and non-functional requirements in the PRS should be consistent with this identified context. If a requirement cannot be traced back to the defined objectives, actors, or context, it may indicate that the requirement is out of scope or that the context needs refinement. System Identification acts as the foundation of the PRS: it scopes the problem and aligns the team on what the product is and where and how it will be used before specifying detailed behaviours.

6.Use Cases#

After establishing the context and scope, the next step is to identify use cases for the product. Use cases capture the high-level functions or interactions that the system must support. Each use case represents a distinct goal or task that an actor (user or external system) needs to accomplish with the help of the product. Defining use cases is a crucial part of deriving functional requirements because it keeps the focus on the intended outcomes and user goals rather than on individual features in isolation.

6.1.Identifying Use Cases#

To ensure comprehensive coverage, use cases are systematically identified by considering the following sources:

  • Actor goals
    For each actor identified in System Identification, it is determined what they need to accomplish with the system. Each distinct goal is a candidate use case.
  • Product lifecycle phases
    All phases the product goes through are considered: factory setup and configuration, installation and commissioning, normal operation, maintenance and servicing, firmware updates, and decommissioning or disposal. Each phase typically yields one or more use cases.
  • Operational modes
    If the system has different modes of operation (e.g., standard mode, external control mode, payment mode), each mode that involves materially different interactions is a candidate use case.
  • External triggers
    All external systems and interfaces from System Identification are identified. For each, consider what events or signals require a system response (e.g., incoming data, start or stop signals, payment pulses).
  • Regulatory or safety obligations
    Mandated functions such as emergency shutdown, self-test, safety interlocks, or compliance-related operations often become use cases in their own right.
  • Shared functionality
    As use cases are identified, functionality that appears across multiple use cases (see the shared-functionality rule below) is extracted into its own use case.

After identification, completeness is verified by checking that every actor has at least one use case, every external interface is exercised by at least one use case, and every operational mode is covered.

6.2.Use Case Overview#

For reference and overview, use cases are listed in an overview table with the following fields:

  • Identifier
    Unique ID to reference the use case, using a sequential numbering scheme (e.g., UC-01, UC-02).
  • Name
    A short, verb-oriented title, unique within the PRS. The name should clearly hint at the objective (e.g., "Configure Network Settings", "Perform System Self-Test").
  • Objective
    The goal the use case aims to accomplish, formulated as an intention (e.g., "Configure the system to access the wireless network", not "The system is configured to access the wireless network"). Think of it as completing the sentence "I want to be able to..." – though this prefix is not included in the actual text.
  • Actors
    The actors involved in the use case. Identify who initiates the use case and any other participants. The system itself is always implicit and doesn't have to be listed.
  • Priority
    The priority level of the use case, indicating its importance, where the five defined levels are: Essential, Secondary, Nice-to-have, Emerging, and Future (see chapter 11 on prioritisation).

6.3.Shared-Functionality Rule#

When multiple use cases require the same functionality – for example, establishing a service connection, authenticating a user, or performing a self-test – that functionality can be extracted into a separate use case rather than duplicating it. The original use cases then become dependent on the shared use case, and this relationship is reflected in the dependency diagram. This keeps each use case focused on a single objective and avoids scattered duplication of scenarios and requirements.

6.4.Use Case Dependencies#

Once the list of use cases is compiled, it is examined whether dependencies exist between them. Sometimes one use case must be completed before another can be performed, or certain use cases share common steps or data. These relationships are represented in a use case dependency diagram. Understanding dependencies is valuable for planning and prioritization: it highlights which functionalities build on others and ensures that prerequisites are addressed first. In addition to the diagram, an optional dependency table can describe the rationale for each dependency.

6.5.Use Case Descriptions#

After identifying all use cases and their interdependencies, the PRS devotes a section to each use case. Each section documents the details needed to understand and later implement that use case. For every use case, the following is included:

  • Description
    A narrative explaining how the actors interact and what the system does. This elaborates on the context and sequence of actions in general terms, before the specific scenarios are written.
  • Objective
    An elaboration of the brief objective from the overview table, providing additional detail on what it means for the use case to be considered successfully completed. Use the same intention-based formulation.
  • Scenario overview
    A table listing all scenarios that will be authored for the use case, with columns: ID, Scenario (short descriptive name), and Result (brief statement of the outcome). If a use case has no failure scenarios, a brief justification follows the table explaining why no realistic failure mode exists.

By structuring the PRS around use cases, functional requirements are organized according to real-world usage. This user-centred approach validates that the product's functions will collectively allow users and systems to achieve their goals. It also makes the PRS easier to understand for stakeholders, as each section focuses on a meaningful capability or interaction.

Use cases also serve as a bridge between high-level stakeholder needs and detailed requirements: every requirement should ideally trace back to enabling a use case.

7.System State Modeling#

Before diving into the specifics of each scenario, a high-level system state model for the product must be defined. The state model describes the various operational states the system can be in and how it transitions between them in response to events or conditions. Its purpose is to provide a shared behavioural context for all scenarios and requirements, ensuring consistency in how the system's modes of operation are understood across the team.

The state model remains abstract: it is not a detailed design of software threads or hardware conditions, but an externally observable view of system behaviour. For example, states might include "Idle", "Active / Running", "Error", "Maintenance Mode", "Shutdown", depending on the nature of the product.

7.1.Modelling Principles#

To create the state model, the following modelling principles apply:

  • Behavioural focus
    States are defined in terms of externally observable behaviour or high-level operation, not in terms of internal software threads, tasks, or hardware specifics. For example, a state named "Data Logging Complete" is better than one named "Buffer XYZ Empty".
  • Meaningful and stable states
    Each state should represent a meaningful mode of operation that persists for some duration or recurs, rather than a momentary internal condition. The state model should be simple enough to remain stable as the design evolves.
  • Complete but minimal
    The set of states should be sufficient to cover all scenarios (so that any scenario step can refer to a state in this model), but should minimize overlap or redundancy. If a new scenario requires a state that is not in the model, update the model. Conversely, do not include states that never appear in any scenario.
  • Explicit decision points
    Decisions in the state flow are explicitly modelled as a two-way branch. In the state modelling these are called "Choice-points".

7.2.Naming Conventions#

The following practical conventions are used:

  • State names use Title Case (each word capitalized) and are phrased either as an ongoing action (e.g., "Awaiting Connection", "Performing Self-Test") or as the conclusion of an action (e.g., "Connected", "Error Detected", "Session Complete"). The name should convey what the system is doing or what condition it has reached, without referencing internal implementation details.
  • Choice-point names use Title Case and are phrased as a binary question ending with a question mark (e.g., "Connection Lost?", "Maximum Reached?", "Payment Sufficient?"). The question must yield a clear yes or no answer that determines which transition path the system follows.

7.3.Elements of the State Model#

The state model is represented with four elements:

State Table#

A table listing each named state and a brief description. Descriptions clarify the system's capabilities or behaviour in that state and avoid implementation language.

Choice-Point Table#

Choice-points represent explicit decision points where the system evaluates a condition and follows one of two paths. They model behavioural branching without embedding logic inside scenarios. The table lists each choice-point by name and its binary evaluation condition. Typical examples include credential verification ("Correct Credentials?"), validation checks ("Self-Test Passed?"), and routing decisions ("Correct Server?").

A choice-point in the state model always has exactly two outgoing transitions: one for "Yes" and one for "No".

Same Condition Evaluated at Multiple Sites#

A frequently encountered modelling pattern is one where the same logical condition is evaluated at two or more different points in the state flow, with different downstream destinations on each outcome. For example:

  • "Is the user authenticated?" asked after a login attempt (Yes → Home, No → Login Error) versus the same question asked before a protected action (Yes → Execute Action, No → Request Re-authentication).
  • "Are sensors nominal?" asked at system startup (Yes → Enter Operating, No → Enter Initialization Error) versus the same question asked mid-operation (Yes → continue, No → Enter Degraded Mode).

In each case, the condition is identical but the evaluation site in the flow is different, and the destinations on Yes and No differ per site. This cannot be modelled with a single choice-point without violating the "exactly two outgoing transitions" rule or introducing ambiguous path qualifiers.

The correct model is to define a separate choice-point for each evaluation site, with each choice-point having its own unique name, its own pair of outgoing transitions, and its own entry in the choice-point table. These are named to make the shared condition and the distinct site explicit – for example, "Credentials Valid?" and "Credentials Valid for Re-authentication?". Once a naming form is picked, it must be used consistently across the document.

A single choice-point reached from multiple sources does not require splitting if all sources route through the choice-point to the same downstream destinations. The choice-point is only split when the downstream destinations differ between callers.

State Transition Table#

A table that enumerates the allowed transitions between states and choice-points. It has the columns: "From" (current state or choice-point), "Event" (the event that triggers the transition), "Description" (a short description of what happens), and "To" (the next state or choice-point).

In this table, choice-points are treated as regular states. Each row captures one transition, and each choice-point contributes exactly two rows – one for its Yes branch and one for its No branch.

Wildcard Source#

A wildcard in the "From" column denotes any state. This is used to express global transitions that apply uniformly regardless of the current state – for example, a critical fault transition, a permission revocation, or a suspension trigger. Practically the wildcard is used sparingly: only when the transition genuinely applies from every state (or almost every state, with documented exceptions).

History Pseudostate#

When a transition must return to whichever real state was most recently active other than the current one, the destination is written as a history reference (often denoted H). History is a pseudostate, not a real state. It is a general-purpose destination that can appear on the Yes or No branch of a choice-point, on a transition out of a simple state, or on any other transition where a fixed destination would require duplicating the source across multiple callers.

Typical uses of History include:

  • Choice-point no-op branch
    A choice-point's "No" outcome returns to the state that triggered the evaluation, rather than a hard-coded state, avoiding duplication of the choice-point per caller.
  • Resumption after a transient condition
    A state entered to handle a transient condition (e.g., a pop-up dialog, a blocking check, a short pause) exits back to whatever was active before.
  • Return from a globally invokable state
    A state reachable from many sources (e.g., a paused or suspended state) returns to its caller via History when the triggering condition clears.
  • Shared exit paths
    Any situation where multiple sources converge on a common state and the common state must route back to each source individually.

History resolves to the most recently visited real state other than the current one. A choice-point is never a History destination. In practice, whenever control reaches a new real state, that state is remembered, and any subsequent transition to History resolves to it.

State Diagram#

A graphical state diagram that visualizes states and transitions. It mirrors the information in the tables – states as nodes and transitions as labelled arrows – and provides an at-a-glance understanding of the system's modes and how one leads to another. The state transition table remains the authoritative enumeration; the diagram is a visual summary.

7.4.Tie-In with Scenarios#

Scenarios reference states from this model as preconditions or postconditions, and may reference states at intermediate points (e.g., "System enters Error state"). By defining the state model up front, all scenarios share a consistent vocabulary for system modes. If a new mode appears necessary during scenario development, update the state model rather than inventing ad-hoc states in the scenario narrative.

8.Use Case Scenarios#

With use cases identified and the state model in place, the PRS next describes scenarios for each use case. Scenario authoring is the process of writing detailed step-by-step flows that show how the system and actors interact to achieve the use case objective – or to handle failures. Scenarios bridge high-level use case descriptions and concrete requirements and serve as a form of high-level acceptance criteria for each use case.

8.1.Scenario Categories#

Each use case typically has multiple scenarios covering different flows:

  • Success Scenario
    The single primary path where the use case objective is fully achieved under normal conditions. Every use case should have exactly one success scenario. This represents the standard, expected flow – the path you would demonstrate to explain "this is how it works." If there appears to be more than one equally valid primary path, the most common or straightforward one can be chosen as the success scenario and the other can be modeled as an alternative success scenario. In rare cases, a second success scenario may be justified; when this happens, document the reason in the scenario overview.
  • Alternative Success Scenarios
    Different paths that still achieve the use case objective but under different conditions or through different means. For example, achieving the same goal via a different interface, with different input data, under different operational modes, or through an uncontrolled variant of the same action (e.g., a graceful session close versus a forced disconnection). Alternative success scenarios are only authored when the alternative path involves materially different system behaviour – not just minor variations in user input.
  • Failure Scenarios
    Situations where the use case objective is not achieved due to an error, fault, or exceptional condition. Each distinct way the use case can fail should be captured in a separate failure scenario. Most use cases have at least one failure scenario; if a use case genuinely has no realistic failure mode, the absence must be explicitly justified in the use case's scenario overview.

To ensure thorough coverage, systematically the following failure categories are considered for each use case:

  • Invalid or rejected input
    Wrong credentials, out-of-range values, malformed data, unauthorized access attempts.
  • Communication and connectivity failures
    Connection timeouts, dropped connections, unreachable external systems or services.
  • Hardware and component failures
    Sensor malfunctions, actuator failures, power supply issues, peripheral device errors.
  • Timeout and expiration
    Operations that exceed allowed time limits, sessions that expire, watchdog triggers.
  • Precondition violations
    Attempting an operation when the system is in the wrong state, missing prerequisites, or required resources are unavailable.
  • Concurrent or conflicting operations
    Multiple actors attempting conflicting actions, race conditions observable at system level.
  • External system failures
    Dependent use cases or external systems returning errors or unexpected responses.

Each failure scenario must define how the system detects the failure, what feedback it provides to the actor, and what safe or recovery state it transitions to.

  • Partial Scenarios
    Reusable scenario fragments that do not independently fulfil a use case objective but capture common sequences of interactions (e.g., establishing a connection, authenticating a user, performing a self-test) that multiple scenarios within the same use case share. Partial scenarios are strictly scoped to their parent use case and must not be referenced from scenarios in other use cases. See the section on partial scenarios below.

8.2.Scenario Format#

Each scenario is contained in its own subsection and documents the following fields, in this order:

  • Result
    The outcome upon completion of the scenario. For a success scenario, this describes the achieved goal (e.g., "Session started, UV lamps active"). For a failure scenario, this describes the resulting safe or error state (e.g., "Connection rejected, system remains in Standby"). For a partial scenario, this describes the intermediate result achieved.
  • Actors (optional)
    By default, a scenario inherits actors from its parent use case. Actors are only specified explicitly when the scenario involves a different subset (e.g., a failure scenario triggered by an external system without human involvement).
  • Preconditions
    Conditions that must be true before the scenario begins. Preconditions reference states from the state model where applicable. The list covers only the conditions required at the start of that scenario; it does not include preconditions that are internal to referenced partial scenarios. However, the successful execution of a partial scenario (or of a dependent use case) may itself be listed as a precondition.
  • Sequence
    Numbered steps describing the interaction between actors and the system. The steps are written in clear behavioural language with no implementation detail.
  • Postconditions
    Conditions that are true after the scenario completes, referencing states from the state model where applicable. Postconditions describe what changed as a result of the scenario – the new state and conditions that are now true because the scenario executed. They do not restate preconditions that were not affected, as this adds clutter without providing information.

8.3.Writing the Sequence#

Each step in the sequence is one of the following:

  • Actor action
    An actor (human or external system) does something that the system must respond to.
  • System response
    The system reacts to an actor action, an external event, or a detected condition.
  • Contextual actor action
    An action performed by an actor entirely outside the system boundary, where the system under development has no role in enabling, receiving, or responding to it (e.g., a user enabling Wi-Fi on their own device, a user plugging in a cable). Contextual actor actions do not generate requirements, but they are included in the sequence to make the interaction flow understandable.

An important distinction: when an actor performs an action through a system-generated artifact or interface (e.g., pressing an acknowledge button on a page served by the system), and the system responds to that action, it is a regular actor action – not a contextual one – even if the action is physically performed on another device. The test is: did the system create the interface that enables the action, and does the system receive and respond to it? If yes, it is a regular actor action and generates requirements.

Example:

  1. The Service User selects the system's wireless network on the Service Device. (contextual – the system has no role in enabling this action)
  2. The system receives the connection request and transitions to Service Mode.
  3. The Service User navigates to the service interface URL using a web browser on the Service Device. (contextual)
  4. The system receives the request and sends the Authentication Page to the Service Device.
  5. The Service User enters credentials in the Authentication Page. (regular actor action – the page is system-generated and the system receives the credentials)
  6. The system validates the credentials.

Steps 1 and 3 are contextual. Step 5 is a regular actor action because the Authentication Page is a system-generated artifact and the system responds to the input.

Triggers and Responses#

Steps follow a trigger-response pattern. A system response is always a reaction to a trigger. The trigger may be:

  • An actor action (e.g., "The Service User presses Start.").
  • An external event (e.g., "The External Timer sends a start signal.").
  • A detected condition (e.g., "The system detects that the temperature exceeds the configured threshold.").

External events and detected conditions do not appear as separate step types – they are embedded in the system response step that reacts to them.

Every trigger must have at least one system response. A single trigger may produce multiple consecutive system responses when the system performs a sequence of actions in reaction (e.g., actor presses Start → system activates lamps → system starts timer → system displays countdown). These are written as separate numbered steps; there is no need to repeat the trigger – the first system response implies the trigger for the subsequent ones.

Conversely, every system response must be traceable to a trigger. If a system step appears to have no trigger, make the triggering condition explicit (e.g., "When the cool-down timer expires, the system deactivates ventilation.").

Referencing Partial Scenarios and Dependent Use Cases#

A step may reference a partial scenario within the same use case, for example:

"3. Partial Scenario UC-01-PS-01 is executed and a wireless connection is established between the Service Device and the system."

A step may also reference a dependent use case by ID with a description of the expected outcome:

"4. Use case UC-04 (Configure Wi-Fi Connection) is performed and the Wi-Fi connection is established."

Referencing specific scenarios or specific steps belonging to another use case is not permitted – see the cross-referencing restriction in the partial-scenarios section below.

8.4.Contextual Preconditions and Postconditions#

Preconditions may include contextual preconditions – conditions about actor readiness or external circumstances that are outside the system boundary but necessary to understand the scenario (e.g., "The Service User knows the correct access credentials", "The Service User has enabled wireless networking on the Service Device"). Contextual preconditions do not generate requirements – they are not verifiable from the system's perspective – but they provide essential context for the scenario to make sense.

Postconditions may similarly include contextual postconditions – conditions about actors or external entities that result from the scenario but are outside the system boundary (e.g., "The Service Device displays the Navigation Page", "The Service User has received the confirmation email"). Contextual postconditions do not generate requirements either, but describe the expected end state from the broader perspective of the interaction.

As an exception, when a scenario could plausibly change something but deliberately does not (e.g., "The existing service session remains unaffected" in a connection-refusal scenario), state this explicitly. Documenting a deliberate non-effect is different from restating an unchanged precondition – it confirms the absence of an expected side-effect.

8.5.Partial Scenario Construction#

In practical PRA projects, after authoring all success, alternative success, and failure scenarios for a use case, the full set for repeated step sequences are reviewed that appear across multiple scenarios. These are then extracted into partial scenarios.

Construction Rules#

The following construction rules apply:

  • A partial scenario is a reusable scenario fragment that does not independently fulfil a use case objective. It captures a common sequence of interactions that multiple scenarios within the same use case share.
  • Partial scenarios are strictly scoped to their parent use case. They must not be referenced from scenarios in other use cases. Cross-use-case reuse is handled through use case dependencies, not through partial scenario references.
  • Partial scenarios may reference other partial scenarios within the same use case in their sequence steps. This allows layered composition of common behaviours (e.g., a "Start Measurement" partial scenario may reference an "Establish Connection" partial scenario). Deep nesting must be avoided – if a chain goes beyond two levels deep, flattening for readability should be considered.
  • Each partial scenario uses the same format as a full scenario (Result, Actors, Preconditions, Sequence, Postconditions). Its result describes an intermediate outcome, not a use case goal. Actors are inherited from the parent use case and specified only when they differ.
  • Partial scenario IDs use the same numbering scheme as other scenarios, with the partial-scenario type marker (e.g., UC-01-PS-01). The use case number always matches the parent use case.

Cross-Referencing Restriction#

A scenario step may reference:

  • A partial scenario within the same use case, by ID with a brief description of what it achieves.
  • A dependent use case, by use case ID with a brief description of the outcome.

A scenario step must never reference:

  • Specific steps within another scenario (e.g., "Steps 1–7 of UC-03-SS-01").
  • A specific scenario belonging to another use case (e.g., "The system executes the flow described in UC-04-SS-01"). The internal scenario structure of a use case is not visible to other use cases.
  • A partial scenario belonging to another use case.

If the same functionality is needed across use cases, it is modeled as a separate use case with a dependency relationship. The dependency diagram captures the relationship, and the referencing step states only what outcome is expected – not how the dependent use case achieves it internally.

Precondition Rules for Referenced Scenarios and Use Cases#

For creating preconditions, the following referencing rules are used:

  • A scenario's precondition list covers only the conditions required at the start of that scenario. It does not include preconditions that are internal to referenced partial scenarios – those are handled within the partial scenario itself.
  • The successful execution of a partial scenario may be listed as a precondition. For example: "Precondition: Partial Scenario UC-01-PS-01 (Wireless Connection Established) has completed successfully."
  • The successful completion of a dependent use case may also be listed as a precondition. For example: "Precondition: Use case UC-02 (Install and Configure System) has been successfully completed." This means the use case objective was achieved, not merely that the use case was attempted.
  • This separation keeps preconditions clean and avoids duplication while making dependencies between scenarios and use cases explicit.

Practical Workflow#

When constructing a PRS, the following practical workflow can be used:

  1. Author all scenarios for a use case first, without worrying about duplication.
  2. Review the scenario set within that use case and identify step sequences that appear two or more times with identical or near-identical wording.
  3. Extract each repeated sequence into a partial scenario within that use case.
  4. Replace the original steps in the parent scenarios with a partial scenario reference.
  5. Verify that the partial scenario's postconditions match what the parent scenario assumes after the reference point.
  6. Check whether any newly created partial scenarios themselves contain repeated sequences that should be extracted into lower-level partial scenarios.
  7. Update the use case's scenario overview to include the new partial scenarios.
  8. If repeated functionality is found across different use cases, model it as a separate use case with appropriate dependencies – never reference specific scenarios or partial scenarios from another use case.

8.6.General Scenario Writing Guidelines#

For writing scenarios, the following general guidelines can be given:

  • Identify triggers and conditions
    Clearly highlight the triggering events that start a scenario or cause a branch. Tying each system response to a trigger or condition ensures requirements derived from the scenario include the context (no requirement stands alone without a condition).
  • Capture system responses for each action
    For every input or trigger in the sequence, explicitly state how the system reacts or what output it produces. This discipline guarantees that no functionality remains implicit.
  • Use clear narrative and avoid implementation jargon
    Write scenarios in terms of user interactions and observable system behaviours. Do not include low-level implementation details; those belong in design. For example, say "System checks that the battery level is sufficient" rather than "System reads register X for battery voltage."
  • Cover alternatives and exceptions
    Author not only the ideal flow but also any alternative flows and failure conditions as separate scenarios. A single use case may have one success scenario, one or more alternative success scenarios (where applicable), and one or more failure scenarios. Each should be written with the same thoroughness.

By the end of scenario authoring, every use case has a collection of scenario narratives that together illustrate all intended behaviours and responses of the system for that use case.

Scenarios are essentially high-level test cases written in prose. Stakeholders can read them to confirm that the product will handle situations as expected, and engineers can use them to derive formal requirements and test cases.

9.Functional Requirements Extraction#

Scenarios provide rich narratives of system behaviour, but to formally specify the product, the PRS must contain explicit, testable requirements derived from those scenarios. Functional requirements extraction is the process of converting scenario descriptions into individual "shall" statements that specify what the system must do. The goal is to ensure that no intended behaviour remains only in narrative form – every action or reaction expected of the system is captured as a clear requirement that can be implemented and verified.

9.1.Methodology#

Not every scenario step becomes a requirement. Only steps where the system has a responsibility, performs an action, makes a decision, produces an output, or changes state become candidates for requirements. Steps describing actor actions alone (without a corresponding system response) do not generate requirements. Contextual actor actions, contextual preconditions, and contextual postconditions – all of which describe interactions or conditions outside the system boundary – do not generate requirements either. The relationship between steps and requirements is flexible:

  • One step may yield one requirement when it describes a single, atomic system behaviour.
  • One step may yield multiple requirements when it describes compound behaviour that should be verified separately.
  • Multiple steps may merge into one requirement when they describe a single coherent operation from a verification perspective.

The functional requirements are listed in a table with the following columns:

  • ID
    A unique identifier following the project's ID scheme. Functional requirements use a format that distinguishes them as product-level and functional (e.g., REQ-PRS-FR-001).
  • Requirement
    A declarative statement using "shall" (the standard wording for a binding requirement), atomic (focused on a single specific behaviour or condition), and including any relevant trigger or condition.
  • Source
    The scenario or partial scenario ID from which the requirement was derived. This reference serves as rationale; no separate rationale field is needed for functional requirements.
  • Acceptance Criteria
    How the team will verify the requirement, typically a brief test description or measurement method.
  • Priority
    Inherited from the parent use case or scenario, or overridden with justification.

9.2.Relationship Between Scenario Steps and Requirements#

Steps in a scenario fall into three categories from the requirements extraction perspective:

  1. Actor actions
    Describe what a user or external system does (e.g., "User presses the Start button"). These do not become requirements themselves but serve as trigger conditions for subsequent system behaviour.
  2. System actions
    Describe what the system does in response (e.g., "System validates sensor calibration"). These are the primary source of functional requirements.
  3. Implied behaviours
    Actions not explicitly stated as steps but implied by preconditions, postconditions, or the scenario context (e.g., logging, state transitions, error handling). These must also be captured as requirements.

9.3.Extraction Process#

The following systematic process ensures complete and consistent extraction.

  • Step 1 – Identify system responsibilities
    Review each scenario step and determine whether the system is performing an action, making a decision, producing output, or changing state. Mark all such steps.
  • Step 2 – Identify trigger conditions
    For each system action, identify the preceding actor action, external event, or detected condition that triggers it. Requirements should not describe system behaviour in isolation; they must specify when that behaviour occurs.
  • Step 3 – Formulate "shall" statements
    Convert each system responsibility into a declarative requirement using the standard "shall" wording. Each requirement should be atomic (addressing a single behaviour), unambiguous (having only one interpretation), and verifiable (testable by inspection, analysis, demonstration, or measurement). Use the pattern: "When [trigger / condition], the system shall [action / behaviour]."
  • Step 4 – Capture implied behaviours
    Review the scenario's preconditions, postconditions, and overall context for behaviours that are assumed but not explicitly stated as steps. Common examples include logging and audit-trail generation, state transitions, data persistence, timeout handling, and resource cleanup.
  • Step 5 – Add verifiable criteria
    Where the scenario describes behaviour qualitatively (e.g., "quickly", "reliably"), refine the requirement to include measurable criteria. Before flagging any value, apply the authority test (Chapter 2): flag with [TBD] only when the authority is the customer/stakeholder or established knowledge and the value is genuinely missing. If the value is fixed by a cited standard or by established knowledge, state it with the citation and do not flag it. If the concrete value is a design or feasibility output, state the functional need and leave the value to System Requirements Analysis – do not flag it as pending, and do not add a feasibility caveat.
  • Step 6 – Verify bidirectional traceability
    Confirm that every system behaviour described in the scenario maps to at least one requirement and that every extracted requirement traces back to a scenario or partial scenario. Requirements extracted from a partial scenario are written once – they are not duplicated for each parent scenario that references the partial scenario. When a scenario step references a dependent use case, do not extract requirements for that use case's functionality; those belong to the dependent use case and are extracted from its own scenarios. The referencing step is a delegation, not a system action, and generates no requirement.

9.4.Common Pitfalls#

Some common pitfalls when extracting the functional requirements are listed below:

  • Missing triggers
    Writing requirements without specifying when the behaviour occurs (e.g., "The system shall validate data" instead of "When data is received, the system shall validate...").
  • Compound requirements
    Combining multiple behaviours into one requirement, making verification ambiguous. Split these into atomic statements.
  • Vague criteria
    Using subjective terms like "fast", "user-friendly", or "reliable" without measurable definitions.
  • Omitting failure behaviour
    Focusing only on success scenarios and neglecting to specify how the system handles errors and exceptions.
  • Implementation bias
    Describing how the system should work internally rather than what externally observable behaviour is required.
  • Extracting requirements from contextual items
    Generating a requirement from a contextual actor action, a contextual precondition, or a contextual postcondition. These are outside the system boundary and do not generate requirements.
  • Mis-flagging values
    Marking a value [TBC]/[TBD] when the authority test (section 2.2) shows it should instead be stated with a citation (established knowledge) or expressed as a functional need and left to System Requirements Analysis (a design or feasibility output). Equally, never attach a feasibility caveat to a requirement; feasibility is evaluated later, not asserted in the PRS.

9.5.Output#

After extraction, the PRS contains a comprehensive list of functional requirements. Each requirement is:

  • Uniquely identified (e.g., REQ-PRS-FR-001).
  • Traceable to its source scenario or partial scenario.
  • Written as a verifiable "shall" statement.
  • Accompanied by acceptance criteria.
  • Assigned a priority.

This systematic extraction ensures that all intended system behaviours are captured as formal requirements, providing a complete and testable specification for design and implementation.

10.Non-Functional Requirements#

In addition to functional requirements (the behaviours and features of the product), a complete PRS includes all the non-functional requirements (NFRs) – the constraints, qualities, and conditions under which the product must operate.

NFRs specify how well the system must perform, how reliable or secure it must be, what standards it must comply with, and other attributes not tied to specific use case behaviours. In high-tech electronic systems, NFRs are often as critical as functional requirements: failure to meet a performance target, regulatory standard, or safety criterion can be just as unacceptable as a missing feature.

10.1.Distinction from Functional Requirements#

Unlike functional requirements, which are extracted from use case scenarios, non-functional requirements typically originate from sources outside the scenario analysis process:

  • Stakeholder constraints and business decisions.
  • Regulatory and certification obligations.
  • Industry standards and best practices.
  • Environmental and operational conditions.
  • Customer specifications and contractual agreements.
  • Lessons learned from previous projects or products.

Because NFRs do not emerge from scenarios, their justification is not inherently documented through traceability. Therefore, each NFR must include an explicit rationale explaining why it exists and what drives its specific value or threshold. This rationale ensures that:

  • Future engineers understand the origin and importance of each constraint.
  • Trade-off decisions can be made with full knowledge of consequences.
  • Requirements are not inadvertently relaxed or removed without proper justification.
  • Auditors and reviewers can verify that all external obligations are addressed.

The rationale field also carries a second responsibility under the authority test (section 2.2): where a quantitative threshold is fixed by a cited standard or by established knowledge rather than by a stakeholder, the rationale names that source. This is what makes the value defensible without a pending flag – a reviewer checks the citation rather than asking the customer to confirm a figure they are not the authority for.

10.2.Structure of the NFR Chapter#

The NFR chapter opens with an Overview section containing a table that lists each NFR category used in this PRS with a short description of what it covers and why it is relevant for this product. The table has columns: Category and Description. This gives readers a quick orientation before the detailed requirements.

After the Overview, each NFR category has its own section that groups all requirements belonging to it. Within each section, every NFR is documented with:

  • ID
    A unique identifier distinguishing it as product-level and non-functional (e.g., REQ-PRS-NFR-001).
  • Requirement
    A "shall" statement with a measurable threshold.
  • Rationale
    Why this requirement exists and why this specific value (naming the source where the value is fixed by a standard or established knowledge).
  • Acceptance Criteria
    How compliance will be verified.
  • Priority
    See chapter 11.

Organizing NFRs by category makes ownership, review, and cross-referencing straightforward.

10.3.Categories of Non-Functional Requirements#

The exact categories vary depending on the product domain. Common categories include, but are not limited to:

  • Performance
    Quantitative targets for performance characteristics such as speed, throughput, capacity, response time, and efficiency. Examples include maximum latency for a critical operation, data processing rates, throughput or bandwidth, and power-consumption limits. In high-speed or real-time electronics, performance may also involve metrics like jitter, bit error rate, or timing accuracy. All such requirements are stated with concrete, measurable values and conditions. Some performance limits are fixed by established human-factors or physical knowledge rather than by a stakeholder – for example, a perceptual-response ceiling for feedback that is to feel instantaneous – and these are stated firmly with the source cited in the rationale, not flagged for confirmation.
  • Reliability and Availability
    Ensuring dependable operation over time. Reliability can include metrics such as Mean Time Between Failures (MTBF), error rates, and fault tolerance. Availability may be specified as a percentage uptime. For mission-critical systems, this category also covers safety requirements and fail-safe behaviour – for example, compliance with a Safety Integrity Level standard, or requirements for redundancy and graceful degradation.
  • Regulatory and Compliance
    Applicable regulations, standards, and certifications. Examples include electromagnetic interference standards, environmental ruggedness standards, safety standards for functional safety, medical-device regulations, communication standards, and security standards. Each compliance requirement is phrased as "The product shall comply with [Standard X]".
  • Environmental Conditions
    Conditions under which the product must operate reliably, such as operating temperature, humidity, altitude, shock, vibration, and ingress protection. Requirements should be testable (e.g., an implied environmental chamber test or shock/vibration test). Standard environmental envelopes (for instance, a recognised climatic class for a given installation type) are an established-knowledge source: state the range and cite the class in the rationale rather than flagging it.
  • Power and Electrical Constraints
    Input voltage range, current consumption limits, battery life expectations, and power-transient or quality requirements. Also efficiency requirements or limits on power consumption for battery-powered devices. Note that an achievable consumption figure is typically a design output: state the functional need (low enough that fleet energy cost stays minor, long enough battery life for the use case) and let System Requirements Analysis determine the concrete figure, rather than flagging a placeholder number.
  • Maintainability and Serviceability
    Requirements ensuring the product can be maintained, serviced, or updated effectively. Examples include modularity, self-diagnostic features, firmware update mechanisms, and Mean Time To Repair targets.
  • Branding and User Experience Constraints
    Adherence to branding guidelines, style guides, or user-experience standards. Industrial design constraints (dimensions, weight, aesthetics) may also be captured here when they impact engineering.

Other categories may be added when relevant (e.g., Security, Data Integrity, Physical Dimensions and Weight), and categories that do not apply to the product may be omitted. Choose categories that reflect the actual constraints and qualities of the product rather than forcing requirements into a fixed template.

10.4.Verifiability of Non-Functional Requirements#

As with functional requirements, each NFR must be stated in a verifiable way: clear metrics, units, and thresholds must be used and subjective or ambiguous phrasing must be avoided.

Quantitative NFRs are where the authority test (Chapter 2) earns its keep, because the temptation to flag every threshold is strongest here. This is applied before flagging:

  • If the value is fixed by a cited standard or by established knowledge, it is stated by naming the source in the rationale – not by flagged it. For instance, a requirement that touch feedback be emitted within roughly 100 ms need not be marked [TBC]: the threshold is set by the human-perception literature on instantaneous response, and the rationale simply cites it. The value is as firm as any other in the document.
  • If the concrete value is a design or feasibility output (achievable power consumption, a physical dimension, an internal timing budget), the functional need is stated and the figure is left to System Requirements Analysis – it is not flagged as pending.
  • An NFR is flagged with [TBC] (stated, needs confirmation) or [TBD] (genuinely missing) only when a stakeholder is the authority – for example, a customer-mandated service life, certification region, or brand constraint. Where possible, such values should already have been raised in the Pre-Draft Triage (Chapter 3).

Any NFR with a feasibility caveat is not annotated. Whether a stated threshold is achievable, and at what cost, is evaluated during System Requirements Analysis and fed back through the loop described in Chapter 2; it is neither asserted nor hedged in the PRS.

10.5.Cross-Referencing with Context#

NFRs are always to be cross-checked against the context and use cases established in earlier chapters. For every environmental condition, regulatory scenario, or operational constraint mentioned in System Identification or the Business Case Background, it is verified that a corresponding NFR exists. For example:

  • If the context states the device will be used in vehicles, it is ensured that there are automotive electrical and environmental requirements.
  • If the target market includes a specific region, it is ensured that certification prerequisites for that region are captured.
  • If the business case mentions a 10-year product lifetime, it is ensured that reliability and component availability requirements reflect this.

This alignment guarantees the PRS comprehensively reflects all external demands on the product.

10.6.Summary#

Non-functional requirements define the quality attributes and constraints that the product must satisfy. Unlike functional requirements extracted from scenarios, NFRs require explicit rationale documentation to preserve the knowledge of why each constraint exists and what value or threshold is mandated. A thorough PRS lists all such requirements with their rationale and acceptance criteria, giving equal weight to NFRs and functional requirements. Both are essential for a successful product.

11.Prioritization#

Not all requirements are of equal importance or urgency. In the PRS, it is valuable to indicate the priority of use cases, scenarios, and individual requirements. Prioritization helps the development team and stakeholders understand which functionality is critical from the start and which can be scheduled for later releases. It directly supports planning activities such as defining a Minimum Viable Product (MVP), scheduling iterative development, and making trade-off decisions when resources are limited.

11.1.Priority Levels#

The PRS uses exactly five priority levels:

  1. Essential
    Required to implement the minimal viable functionality of the product. Core capabilities without which the product would not be viable or meet its primary objectives. Essential items typically form the MVP and are implemented first.
  2. Secondary
    Required to extend functionality beyond the core. Important for the full product vision but implemented after essentials are in place. Significantly enhances value or usability.
  3. Nice-to-have
    Addresses situations that are rarely encountered or apply to a small subset of users, or features that are desirable but not critical. These may be implemented if time and resources permit, or deferred to later versions. Not all nice-to-have scenarios are fully elaborated in early PRS versions.
  4. Emerging
    Does not have to be implemented. Typically emerges out of combinations of implemented use cases. Added for completeness.
  5. Future
    Speculative or future-expansion ideas recognized but out of current scope. Acknowledged as placeholders for future stakeholder requests, not planned for current development.

Assigning priorities is typically based on business value, user impact, implementation risk, dependencies, and technical complexity. High business value and low risk tend to be essential; low value or high effort tend to be nice-to-have or deferred.

11.2.Prioritization Summary#

The PRS includes a Prioritization Summary chapter that organizes all requirements – functional and non-functional – into separate sections by priority level: Essential, Secondary, Nice-to-have, Emerging, and Future. Each section lists the individual requirement IDs (not counts or group summaries) with a short description and a brief justification for each classification.

Dependency Consistency Check#

Before finalizing the grouping, a dependency consistency check is performed using the following guidelines:

  1. For every requirement in a given priority level, verify whether it depends on any requirement assigned to a lower priority level.
  2. If such a cross-priority dependency exists, resolve it by either:
  3. Promoting the lower-priority requirement to match the higher-priority one (preferred when the dependency is hard and unavoidable), or
  4. Demoting the higher-priority requirement to match the lower-priority one (only when re-evaluation shows the requirement is not as critical as initially assumed).
  5. Flag every promotion or demotion with a brief justification so the rationale is transparent to stakeholders.

Where a priority was adjusted during the dependency check, the original priority is noted and the reason for the change alongside the requirement.

11.3.Use of Prioritization in the Project#

Using these categories helps structure the project plan. Essential and Secondary use cases typically form the basis of the first complete PRS draft and the initial development iteration (the MVP or first release). Nice-to-have items are slated for subsequent releases or left for re-evaluation. Emerging and Future items may not be implemented at all, but documenting them ensures the team is aware and can accommodate them architecturally where sensible.

The benefit of including prioritization is that it aligns expectations: stakeholders know which features will be delivered first, and developers know where to focus if trade-offs are needed. It also aids in making decisions during development – if unforeseen challenges arise, lower-priority items can be dropped or postponed to protect the schedule or budget for higher-priority ones.

12.Acceptance Criteria and Verifiability#

One of the hallmarks of a good requirement is that it is verifiable – there is a clear, objective way to determine if the final product meets it. In the PRS, acceptance criteria are defined alongside requirements to describe the conditions or tests that will be used to verify compliance. This ensures that every requirement is not only clear in intent but also paired with a plan for how to test or measure it.

12.1.Defining Clear Acceptance Criteria#

For each requirement, the PRS lists how the team will verify it. Acceptance criteria often take the form of a brief test description or measurement method. For example:

  • Requirement: "The power supply shall support input from 100–240 VAC." – Acceptance criterion: "Test the device across the full 100 VAC to 240 VAC range; it must function normally without errors or damage."
  • Requirement: "The data interface shall sustain a throughput of 1 Gbps." – Acceptance criterion: "Measure data transfer using standard tool X under conditions Y; at least 1 Gbps is maintained 90% of the time."

Essentially, acceptance criteria answer the question: "How will we know this requirement is fulfilled?"

12.2.Verifiability Early in the Lifecycle#

Defining acceptance criteria during requirements analysis has two major benefits. First, it forces clarification of the requirement – if the team struggles to describe how to test a requirement, that is a signal that the requirement is too vague or subjective. Defining acceptance criteria often leads to refining the requirement wording for clarity. Second, it uncovers special testing needs or resources early. High-tech products may need specialized test equipment or environments (altitude chambers, EMC chambers, penetration-testing services). By identifying these needs in the PRS, the project can plan for them in budget and timeline well in advance.

Note that defining how a requirement will be verified is distinct from establishing whether it can be met affordably. Acceptance criteria describe the test that confirms the requirement is satisfied by a built product; they do not assert that the requirement is achievable. Achievability is a feasibility question addressed in System Requirements Analysis, not in the PRS – consistent with the feasibility-out-of-scope principle in Chapter 2.

12.3.Examples of Verifiable vs. Non-Verifiable Requirements#

The PRS strives to contain only verifiable requirements. Vague requirements should be avoided or rephrased.

  • Not verifiable: "The system shall be easy to use." – What does "easy" mean and how is it tested?
  • Verifiable: "A first-time user shall be able to perform [a specific key task] within 5 minutes without referring to a manual." – Measurable through observation or usability study.
  • Not verifiable: "The device shall not overheat." – No conditions defined.
  • Verifiable: "The device shall operate within specifications (no thermal shutdown or data errors) at ambient temperatures up to 50 °C for at least 24 hours." – Clear conditions and pass/fail criteria.

Each requirement should be unambiguous and tied to an acceptance method, whether functional testing, measurement, inspection, or analysis. If a requirement cannot be tested or verified somehow, it is reconsidered whether it is a valid requirement or reword it until it is verifiable.

12.4.Compliance and Certification Acceptance#

For requirements involving compliance with standards or regulations, the acceptance criteria often involve completing official tests or obtaining certifications. The PRS should state these explicitly. For example:

  • Requirement: "The product shall comply with EMI standard EN 55032 Class B." – Acceptance: "Pass EMI compliance testing per EN 55032 Class B in an accredited lab."
  • Requirement: "The system shall meet Safety Integrity Level 2 (SIL-2)." – Acceptance: "Independent assessment or unit testing to SIL-2 requirements by a certified body."

Stating these criteria makes clear that the definition of done for such a requirement includes the certification or test report, not just internal verification.

12.5.Integrating Acceptance Criteria with Requirements#

By incorporating acceptance criteria in the PRS, the document becomes more than just a list of requirements – it doubles as a high-level validation plan. It gives stakeholders confidence that for each requirement there is a way to prove it has been met. This alignment with testability from the start of the project greatly reduces the risk that, late in the project, someone asks "How do we test this?" and finds it problematic. The key is that for every "The system shall..." statement, you can answer "How will we test that?" immediately.

13.Requirements Listing and Traceability#

Once all functional and non-functional requirements have been identified, the PRS can organise them for easy reference and establish traceability mechanisms. This final step ensures that requirements are accessible throughout the development lifecycle.

Note that this may also be handled by external tooling which extracts the requirements from the PRS as described in section 13.3.

13.1.Requirements Listing#

The PRS presents all functional requirements as a table organized per use case and scenario, and all non-functional requirements as tables organized per category. Each requirement has a unique identifier and the metadata specified in earlier chapters:

  • Functional requirements
    ID, Requirement, Source, Acceptance Criteria, Priority.
  • Non-functional requirements
    ID, Requirement, Rationale, Acceptance Criteria, Priority.

The identification scheme distinguishes functional and non-functional requirements explicitly (e.g., REQ-PRS-FR-nnn for functional, REQ-PRS-NFR-nnn for non-functional). IDs remain stable throughout the product lifecycle and are used for traceability to system requirements, design elements, and test cases.

13.2.Traceability#

As development progresses into design, implementation, and testing, maintaining traceability is crucial – the ability to trace each high-level requirement to lower-level requirements, design elements, and test cases, and vice versa. The PRS is the top level of this trace. Therefore, any requirements in later documents (for example, the System Requirements Specification or test plans) link back to one or more PRS requirements. If a lower-level requirement or design component is introduced, it cites the PRS requirement it satisfies. This hierarchical linkage ensures that:

  • Nothing is built that does not tie to a product requirement (preventing scope creep).
  • All product requirements are being addressed (completeness check).

A common tool for managing this is a Requirements Traceability Matrix (RTM), typically maintained in a spreadsheet or requirements management tool. An RTM lists PRS requirements in one column and references to corresponding system requirements, design modules, and test cases in other columns. The PRS itself can note that an RTM is maintained, or include a simple form of it to demonstrate coverage.

All lower-level requirements (and even design specifications) should trace back to one or more PRS requirements. If a design requirement is found with no parent in the PRS, question why it exists (was it an unapproved feature, or does the PRS need an update?). Conversely, if a PRS requirement is not mapped to any implementation or test, it risks being forgotten – traceability flags that as well.

Maintaining traceability is particularly important in complex, high-reliability projects (aerospace, medical, automotive safety systems) where formal proof of meeting all requirements is needed. Regulatory standards often demand a trace matrix in deliverables. Even outside regulated industries, it is a best practice because it structures the verification effort and change management: if a PRS requirement changes, traceability lets you quickly find what design documents and tests need updating.

13.3.Tool Support#

The PRS document may be authored in Markdown or a word processor for human readability, but the requirements list and traceability are often managed in a database or dedicated requirements management tool. The PRS remains consistent with that database. Some teams include an export or snapshot from the database as the requirements list in the PRS. The approach may vary, but the key is that identifiers are consistent and the source of truth is maintained.

14.Reference Materials#

A comprehensive PRS ends with a Reference Materials chapter that provides supporting information helping readers interpret and use the requirements. This chapter typically includes:

  • Glossary of Terms and Acronyms
    Defines every acronym, abbreviation, and domain-specific term used in the document. High-tech projects often involve jargon (e.g., SIL – Safety Integrity Level, MTBF – Mean Time Between Failures, FFT – Fast Fourier Transform). Listing these ensures consistent interpretation across stakeholders. For each term, provide a brief definition. Even common terms can be included if there is any chance of ambiguity.
  • Referenced Standards and Documents
    Lists all external standards, specifications, regulatory documents, and corporate documents cited in the PRS, with full title and edition or year where applicable. This includes any standards or published sources cited in NFR rationale to substantiate a value under the authority test (Chapter 2) – for example, a human-factors reference behind a perceptual-response threshold or a climatic-class standard behind an environmental range.
  • Source Documents
    Lists the customer-provided input documents (the Customer Requirements Specification and any background material such as market research, competitor analyses, technical white papers, or standards excerpts) that were used as the basis for this PRS. This creates a clear trail from high-level sources to the PRS content. Where a Pre-Draft Triage (Chapter 3) was conducted, the recorded triage responses are also listed here as a source.
  • Preliminary Data or Diagrams
    Conceptual diagrams, context or use case diagrams, or any preliminary interface illustrations that help in understanding the requirements.

14.1.Appendices#

Background information from supporting documents that is important for interpreting or substantiating the PRS but does not fit within the numbered chapters is placed in appendices following the Reference Materials chapter. Appendices are suitable for:

  • Extended background material (market data, technical white papers, standards excerpts).
  • Detailed reference lists (e.g., a full enumeration of configuration parameters whose individual values are expressed as requirements in the main body).
  • An Open Items Summary consolidating the genuine stakeholder-authority [TBD] and [TBC] markers for review. Per the authority test (Chapter 2), this summary lists only items whose authority is the customer or another stakeholder; it does not list values resolved by citation, nor values deferred to System Requirements Analysis as design or feasibility outputs.
  • Preliminary mechanical drawings, mockups, or other visual reference material.

The Reference Materials chapter and its appendices ensure the PRS is relatively self-contained: a new team member or external stakeholder reading the document can find the meaning of any term, identify referenced documents, and access supplementary context without hunting through other files.

15.Document Template#

Following from the guidelines above, the PRS is structured as follows:

# Chapter Content
1 Introduction Purpose, scope, intended audience, document structure.
2 Document Conventions Numbering schemes for use cases, scenarios, and requirements; "shall" / "should" / "may" conventions; [TBD] and [TBC] markers and the authority test that governs their use; the principle that the PRS is feasibility-unconstrained (feasibility is evaluated in System Requirements Analysis, not asserted in the PRS); heading and numbering convention.
3 Business Case Background Product intent and market context; target customer segment; competitive landscape; commercial assumptions (volume, lifetime, cost strategy, certification scope), informed where possible by a pre-draft triage of customer-authority facts.
4 System Identification Main product objective; product context; system actors (human and external-system subsections, including generalized actors); product elements in scope; external interfaces (by type, such as physical and logical); system artifacts (by type, such as data and physical, including UI artifacts); context diagram.
5 Use Cases Use case overview listing ID, name, objective, actors, and priority; use case dependency diagram (with optional dependency table); narrative description, objective, and scenario overview for each use case.
6 System State Model State table; choice-point table (including distinct entries for shared-condition choice-points at different sites where applicable); state transition table (supporting wildcard sources and History destinations where needed); state diagram.
7 Use Case Scenarios Per use case, one success scenario, zero or more alternative success scenarios, zero or more failure scenarios (or explicit justification for their absence), and any partial scenarios identified during deduplication. Each scenario has Result, Actors (where differing from the use case), Preconditions, Sequence, and Postconditions.
8 Functional Requirements "Shall" statements extracted from scenarios and partial scenarios. Each requirement: ID (REQ-PRS-FR-nnn), Requirement, Source, Acceptance Criteria, Priority.
9 Non-Functional Requirements Overview section listing NFR categories used, followed by sections per category. Each requirement: ID (REQ-PRS-NFR-nnn), Requirement, Rationale, Acceptance Criteria, Priority. Quantitative values follow the authority test: cited where fixed by a standard or established knowledge, expressed as a need and deferred to System Requirements Analysis where they are design or feasibility outputs, and flagged only where a stakeholder is the authority.
10 Prioritization Summary All requirements are organized into separate sections by priority level (Essential, Secondary, Nice-to-have, Emerging, Future) with individual IDs, short descriptions, and justifications, including notes where priorities were adjusted through the dependency consistency check.
11 Reference Materials Glossary; referenced standards and documents (including sources cited under the authority test); source documents (including any recorded pre-draft triage responses); preliminary diagrams or conceptual models.
A…Z Appendices Additional background information relevant to the PRS but not part of the numbered chapters, including an Open Items Summary of genuine stakeholder-authority [TBD]/[TBC] items where used.

This structure moves logically from context through behaviour to formal requirements, keeping everything solution-neutral, feasibility-unconstrained, and verifiable.

1.Introduction#

The System Requirements Analysis (SRA) phase is the second stage of the structured pre-development process, following the completion of the Product Requirements Analysis (PRA) phase.

In the PRA, a Product Requirements Specification (PRS) is created that clearly defines what the product must do and how it should behave from an end-user and stakeholder perspective, capturing the product's intended functions, features, and constraints. This is done without prescribing implementation choices, except where unavoidable due to constraints or a-priori decisions.

The SRA phase takes the PRS as input and focuses on how those product requirements can be realized through technical means. In other words, it performs the technical translation of each product requirement into feasible system-level solutions, identifying the architectural implications and potential design directions.

This phase bridges the gap between product intent and concrete design by developing system architectures, analyzing implementation concepts, and defining technical requirements. Unlike the PRA, which avoids making design decisions, the SRA embraces technical exploration. Architecture options are evaluated, technologies are assessed, and where necessary, proof-of-principle prototypes are built to validate feasibility. By the end of the phase, the engineering team has high confidence that the product requirements are technically achievable and well-understood.

1.1.Relationship to the PRS#

The SRA has three structural obligations toward the PRS, each addressed by a dedicated mechanism in these guidelines:

  • Feasibility evaluation
    The PRS is feasibility-unconstrained by design: it states what the product must do, and the SRA evaluates whether – and at what cost – each requirement is achievable. Where a requirement proves technically infeasible or economically impractical, the finding is fed back to the customer through the structured change process defined in Chapter 9 (PRS Feedback and Change Control). This feedback loop is intended and may occur several times.
  • Resolution of deferred values
    The PRS authority test deliberately defers engineering-authority values (e.g., achievable power consumption, timing budgets, environmental margins, physical dimensions, and similar figures) to this phase. The PRS states the functional need; the SRA determines the concrete value. Chapter 5 (Technical Budgeting and Value Resolution) defines the activity that collects, allocates, and resolves these values so that none remains dangling when the SRS is baselined.
  • Behavioural coverage
    The PRS system state model, use cases, and scenarios define the externally observable behaviour the architecture must realize. The architecture definition in Chapter 2 includes explicit coverage checks (including state-model ownership) to guarantee that every behavioural element of the PRS has an architectural home.

1.2.Deliverables#

The SRA phase produces the following key deliverables:

  • System Architecture
    A high-level decomposition of the system into functional modules, with complete connection tables, state-model ownership, and an architecture diagram.
  • Concept Selection Table
    For each functional module, a documented evaluation of implementation options, including classification, feasibility, risk, and rationale for the selected concept.
  • Proof-of-Concepts
    Targeted prototype implementations, each governed by a prototype charter, to validate critical or uncertain aspects of a proposed concept.
  • Technical Budgets and Resolved Values
    System-level budgets (power, timing, mass, cost, and others as applicable) allocated across functional modules, and concrete values for the engineering-authority figures the PRS deferred to this phase.
  • Device Architecture
    A mapping of functional modules to hardware, embedded software, FPGA (where applicable), and mechanical components, including physical interface definitions.
  • Design Risk Analysis (DFMEA)
    A structured failure-mode evaluation of the architecture, with documented rating scales, mitigations, and (for connected products) a security threat analysis.
  • System Requirements Specification (SRS)
    A detailed, verifiable, and traceable set of system-level requirements derived from the PRS and from SRA findings.
  • Preliminary Bill of Materials and Cost Estimate
    An initial component list and cost analysis, evaluated against the commercial assumptions in the PRS Business Case Background.
  • Initial Product Test Plan
    A first version of the test strategy describing how product and system requirements will be verified.
  • PRS Change Proposals
    Where applicable, formally documented proposals for adjusting the PRS based on feasibility findings.

1.3.Hand-off to Product Development Planning#

The SRA deliverables are constructed to feed directly into the Product Development Planning and Estimation phase:

  • The Functional Module Table provides a natural work breakdown structure: each module can become a work package with clear ownership.
  • The Concept Selection Table makes effort drivers visible: trivial concepts imply routine effort, balanced concepts imply design effort, and exploratory concepts imply scheduled feasibility work.
  • The DFMEA seeds the project risk register and identifies verification activities that must be budgeted.
  • The Technical Budgets, preliminary BoM, and Initial Product Test Plan ground the cost, schedule, and test-infrastructure estimates in concrete engineering data.

Keeping this downstream consumption in mind while producing each deliverable avoids rework during planning.

2.System Architecture#

2.1.Objective#

The first major technical activity in the SRA phase is defining the System Architecture through a process of functional decomposition. This involves translating the functional requirements from the PRS into a structured representation of the system's internal organization. The result is a high-level view of the system, broken down into discrete functional modules that collectively define how the system will perform what it is intended to do.

At this stage the architecture remains implementation-technology agnostic: it groups related functionality and defines responsibilities and connections, but does not yet assign technologies, components, or engineering domains. That assignment happens in the Device Architecture, Chapter 6. Note that this is a different notion than the solution neutrality of the PRS: the PRS avoids prescribing any internal structure at all, whereas the System Architecture deliberately defines internal structure while deferring technology choices.

2.2.Outputs#

The System Architecture activity produces the following artifacts, all of which are mutually consistent and together form the architectural baseline carried forward into the rest of the SRA phase:

  • The Functional Module Table, listing each functional module with its responsibilities and PRS traceability.
  • The Internal Connection Table, listing every connection between two functional modules.
  • The External Connection Table, listing every connection between a functional module and an External Interface as defined in the External Interfaces section of the PRS System Identification chapter.
  • The Operational Connection Table, listing every connection between a System Actor and an External Interface.
  • The Actor Cooperation Table, listing every cooperation between two System Actors that is required for the system to be used as intended.
  • The State Model Ownership Table, recording which functional module owns each state-model responsibility.
  • The Architecture Diagram, providing a single visual overview of the modules, interfaces, actors, and connections.

Note on PRS references. Throughout these guidelines, PRS content is referenced by chapter and section name (e.g., "the System Actors section of the PRS System Identification chapter") rather than by section number, because section numbering may vary between PRS documents. Within a concrete project, references should use the actual section numbers of that project's PRS.

2.3.Process#

The process comprises seven steps as described in the following sections.

Step 1Defining Functional Modules#

The architecture definition begins by analyzing the product's main functions, which are typically derived from the PRS use cases and scenarios. These functions are then grouped into logically cohesive Functional Modules, each encapsulating a set of related responsibilities and behaviours. For example, a typical product might include modules such as:

  • User Interface – handling user inputs and system feedback
  • Sensor Module – acquiring and preprocessing sensor data
  • Control Unit – implementing decision logic or feedback control
  • Power Management – managing power supply, charging, or battery status
  • Communication – managing external interfaces or wireless connectivity
  • Mechanical Frame – providing structural or motion-related functions

This decomposition is driven by both functional clustering and anticipated architectural boundaries (e.g., natural software or hardware separations), but without yet assigning implementation technology.

The result of the decomposition is specified in the Functional Module Table with the following specified for each Functional Module:

  • A stable identifier of the form FM-nn (Functional Module) for reference convenience.
  • The full name of the Functional Module.
  • The Primary Responsibility of the Functional Module.
  • The mapped PRS elements, containing requirement IDs and references to PRS use cases and sections.

Step 2Defining the Interconnections#

Functional Modules typically interact with each other; these interactions are captured as interconnections in the Internal Connection Table. For each interconnection the following is specified:

  • A stable identifier of the form IC-nn (Internal Connection), used to reference the connection from later artifacts such as functional module descriptions, the DFMEA, and the SRS.
  • The From and To functional modules.
  • The direction: either Directed (flowing From → To) or Bidirectional. There is no "In" direction: a connection that would be recorded as "In" is instead recorded with the From and To modules swapped. This keeps the table unambiguous – the From module is always the source of a directed connection.
  • A short description of the payload or purpose – what data, control signal, event, or service flows on the connection. For bidirectional connections, the payload description splits the two halves explicitly, e.g., "From → To: state notifications and remaining-time updates. To → From: user inputs (Start/Stop, Pause)."
  • The rationale explains why the connection is required, typically by reference to the PRS use cases, scenarios, or non-functional requirements that drive it.

A connection is recorded as Bidirectional only when both directions are required as part of normal operation. A request followed by a transient acknowledgement is recorded as a single directed connection rather than as bidirectional.

Some Functional Modules – typically persistent data stores, shared services such as branding or localization, and operating-power distribution – are connected to many other modules through a single repeated pattern. Enumerating every such connection individually adds rows that carry little information and obscures the genuinely architecturally significant connections. The Internal Connection Table may therefore list only the connections that depart from such a pattern, and provides a note in the table which describes the omitted pattern explicitly (for example, "read once at boot to load operational parameters") and lists which modules are covered by the pattern.

This keeps the table readable without losing completeness, since the omitted connections remain verifiable from the note. The same simplification applies to the diagram, where cross-cutting fan-out can be shown to representative consumers only.

Step 3Connecting the External Interfaces#

In the External Interfaces section of the PRS System Identification chapter, the product's External Interfaces were identified. The Functional Modules that handle each External Interface must now be identified. The result is captured in the External Connection Table where for each connection the following is specified:

  • A stable identifier of the form EC-nn (External Connection).
  • The Functional Module involved.
  • The External Interface as named in the PRS.
  • The direction of the connection, given from the perspective of the Functional Module: Out, In, or Bidirectional.
  • The rationale explaining why the connection is required.

Note that multiple External Interfaces may connect to a single Functional Module. The opposite situation, where multiple Functional Modules connect to a single External Interface, is permitted only when the External Interface is genuinely composite and the architectural treatment of the parts differs.

Step 4Connecting the System Actors#

In the System Actors section of the PRS System Identification chapter, the System Actors were identified. These System Actors do not directly interface with the Functional Modules, but instead connect to the defined External Interfaces.

The result is captured in the Operational Connection Table where for each connection the following is specified:

  • A stable identifier of the form OC-nn (Operational Connection).
  • The System Actor involved.
  • The External Interface as named in the PRS.
  • The direction of the connection, given from the perspective of the System Actor: Out, In, or Bidirectional.
  • The description that explains why the connection is required.

Some System Actors do not interface directly with an External Interface, but instead cooperate with another Actor to perform a certain functionality. These connections are captured in the next step.

Step 5Capturing System Actor Cooperation#

The cooperation between System Actors is captured in the Actor Cooperation Table. This also includes the case mentioned in Step 4, where a System Actor reaches the system only through another Actor – for example, a Service User using a web browser on a Service Device that is itself connected via Wi-Fi.

For each cooperation the following is specified:

  • A stable identifier of the form AC-nn (Actor Cooperation).
  • The System Actor involved.
  • The Cooperating System Actor.
  • The direction of the cooperation, given from the perspective of the System Actor: Out, In, or Bidirectional.
  • The description of the cooperation.

Note that listing the cooperation between System Actors ensures that all defined System Actors appear in the System Architecture and thus in the Architecture Diagram.

Step 6Verifying State Model Coverage#

The PRS contains a system state model: states, choice-points, and transitions that define the externally observable modes of the product. The architecture must be able to realize this model, and the responsibility for doing so must have a clear owner. This step records that ownership in the State Model Ownership Table, which specifies:

  • Which Functional Module owns mode management – i.e., maintains the current system state and authorizes transitions. This is normally exactly one module; if mode management is genuinely distributed, the division of authority is documented explicitly.
  • For each choice-point, which Functional Module evaluates the condition (e.g., credential validation, self-test result, threshold detection).
  • For each global transition (wildcard-source transitions in the PRS, such as critical-fault or suspension triggers), which module detects the triggering event and how the transition is propagated to the rest of the system.
  • For History-based returns, which module is responsible for remembering and restoring the prior state.

This check routinely surfaces missing modules or connections – for example, a fault state with no module that can detect the fault, or a mode change that several modules must observe but for which no notification connection exists. Resolve such findings by updating the module set and connection tables before proceeding.

Step 7Creating the Architecture Diagram#

The final step is to use the results from the previous steps to construct the Architecture Diagram. This is formatted as a block-level diagram showing:

  • The identified Functional Modules.
  • The External Interfaces as defined in the PRS.
  • The connected System Actors as defined in the PRS.
  • All connections enumerated in the Internal, External, Operational, and Actor Cooperation Tables.

To make the diagram useful as a navigable index into the tables, it observes two conventions:

  • Distinct visual representations are used for the three element types (Functional Modules, External Interfaces, System Actors), so that the reader can identify the kind of each element at a glance.
  • Every connection is labelled with its identifier (IC-nn, EC-nn, OC-nn, or AC-nn), so that any connection in the diagram can be looked up directly in the corresponding table.

Although this is the last step, the Architecture Diagram is placed first in the System Architecture chapter to serve as the initial visual overview for the reader.

2.4.Completeness Checks#

Before the architecture baseline is carried forward, verify:

  • Every functional requirement in the PRS maps to at least one Functional Module (and every module maps back to PRS elements – a module with no PRS trace indicates scope creep or a missing PRS update).
  • Every External Interface in the PRS appears in exactly one External Connection Table entry, or in more than one only under the composite-interface exception of Step 3.
  • Every System Actor in the PRS appears in the Operational Connection Table or the Actor Cooperation Table.
  • Every state, choice-point, global transition, and History return in the PRS state model has an owner in the State Model Ownership Table.
  • Every artifact in the PRS System Identification chapter is carried by at least one connection (an artifact that crosses the system boundary must have a path through an External Connection).

2.5.Maintenance#

The connection tables are kept consistent with the architecture diagram throughout the SRA phase. When concept analysis, prototyping, or design risk analysis surfaces an architectural change – a new connection, a removed one, or a change of direction – both the diagram and the tables are updated together, with the connection identifiers preserved across changes wherever the underlying connection's purpose remains the same.

2.6.Role in Project Planning#

The System Architecture serves as a foundation for downstream design and planning by:

  • providing a clear technical vision of the product's structure, supporting internal alignment across disciplines.
  • defining a natural work breakdown structure (WBS) for engineering teams where each module can become a work package, enabling parallel development and clearer ownership.
  • supporting risk identification by isolating complex or novel functions that may need further investigation or prototyping.
  • providing early visibility to the customer on how their product requirements are understood and organized, and thus supporting quoting, resource planning, and negotiation.

Because of its central role, the System Architecture is typically reviewed with internal stakeholders and the customer to ensure shared understanding and agreement before proceeding to concept evaluation or detailed design.

3.Concept Analysis#

3.1.Objective#

Once the System Architecture has been defined, the next step is to determine how each functional module can be implemented. This is done through concept analysis, in which different implementation approaches – referred to as concepts – are evaluated for feasibility, complexity, and suitability.

Not all functional modules carry the same level of uncertainty or design freedom. Some have well-understood, standard solutions; others require trade-off decisions; and some present significant technical unknowns. Concept analysis identifies and classifies these situations to ensure informed, justifiable design choices.

3.2.Classification of Concepts#

Each functional module is classified into one of three categories:

  • Trivial Concepts
    For some functional modules, there is a single clear and reasonable solution that fulfills all the functional and non-functional requirements. These are referred to as trivial concepts, not because they are unimportant, but because the implementation path is obvious and carries minimal uncertainty. Typical indicators are established solutions, industry standards, or existing building blocks that fit the need without significant adaptation. The required effort is minimal. The decision is straightforward but is still documented, including confirmation that the solution satisfies the applicable requirements.
  • Balanced Concepts
    In many cases, multiple viable implementation approaches are available, each with distinct trade-offs. These are balanced concepts and require a more structured analysis to select the most appropriate solution. Evaluation is done by performing a trade-off study based on defined criteria, such as performance, cost, power consumption, availability, integration effort, or maturity of the technology. The considered options must be clearly stated in the documentation, containing the rationale for selection and the expected implications of the decision. This transparency supports internal alignment and provides traceability to the design rationale. The outcome is a well-founded, defensible concept choice aligned with product priorities and project constraints.
  • Exploratory Concepts
    In some cases, the feasibility of implementing a function is uncertain or relies on novel or unproven technologies. These are exploratory concepts and represent higher technical or project risk. Characteristics are the use of new or untested technology in the intended application, requirements that push known technical limits, or lack of data or supplier experience. The approach is to identify key uncertainties or risks, plan and execute feasibility studies or early prototypes (Chapter 4), or explore multiple options in parallel if needed. This may lead to refinement of requirements – either tightening or relaxing them based on evidence. Where a requirement proves infeasible or cost-prohibitive, a PRS change proposal is raised through the process in Chapter 9.

3.3.The Concept Selection Table#

The results of concept analysis are recorded in the Concept Selection Table, the defined artifact of this activity. It contains one row per functional module, with the following specified for each:

  • The FM-id – the functional module identifier from the Functional Module Table.
  • The Classification – Trivial / Balanced / Exploratory.
  • The Options Considered – the implementation options evaluated. For trivial concepts, the single obvious solution.
  • The Selected Concept – the chosen approach, or "pending" while a prototype is open.
  • The Rationale – why this concept was selected; for balanced concepts, a reference to the trade-off study; for trivial concepts, confirmation that the solution satisfies the applicable requirements.
  • The Status – Decided / Pending Prototype (with reference to the prototype charter, Chapter 4) / Pending PRS Change (with reference to the change proposal, Chapter 9).

For balanced concepts, the underlying trade-off study is documented separately (or as an annex) and referenced from the table: the evaluation criteria, the weighting or priority of those criteria (derived from PRS priorities and the Business Case Background), the scoring of each option, and the implications of the selection.

The Concept Selection Table is the auditable record of every implementation decision made during the SRA, and it is one of the primary artifacts reviewed with the customer.

3.4.Purpose of Categorization#

Categorizing each functional module as trivial, balanced, or exploratory helps the engineering team:

  • Allocate analysis and development effort appropriately
  • Focus attention on modules that pose the greatest uncertainty or risk
  • Communicate clearly with stakeholders about the maturity and risk level of different parts of the system
  • Support estimation, planning, and quoting efforts by making effort drivers visible early

This classification also supports project management and customer dialogue. If a key function is identified as exploratory, it flags the need for additional time or prototyping in the schedule and may require a decision point before proceeding with detailed design.

4.Prototyping and Feasibility Validation#

For functional modules classified as exploratory, targeted prototyping may be required to assess technical feasibility and reduce risk.

Prototypes focus on validating critical aspects of a concept – such as performance, integration, or manufacturability – that cannot be confirmed through analysis alone. Depending on the complexity, this can range from quick bench tests to more elaborate engineering efforts. The goal is to obtain just enough insight to make a confident concept decision.

4.1.Prototype Charter#

Before any prototype is built, a short prototype charter is recorded. The charter prevents prototyping from drifting into open-ended engineering and guards against confirmation bias ("it sort of worked"). It defines, in advance:

  • The feasibility question the prototype answers, stated as a single, decidable question (e.g., "Can the sensing approach achieve the required resolution at the stated ambient temperature range?").
  • Pass/fail criteria – the objective, measurable conditions under which the answer is "yes". These are defined before the prototype is built, never after.
  • Scope and fidelity – what is deliberately not representative in the prototype (e.g., mechanical mounting, production tolerances) so that the conclusion is not over-extended.
  • Effort cap – the maximum effort allocated. If the question cannot be answered within the cap, this is escalated rather than silently extended.

4.2.Execution Guidelines#

Efforts remain minimal and focused:

  • Build only what is needed to answer the charter's feasibility question.
  • Use simple setups where possible (e.g., breadboards, simulations, 3D prints).
  • Validate any critical manufacturing processes early if they pose risk.

If the required effort exceeds the resources allocated for this phase, this must be discussed with the customer, or planned as a separate feasibility track.

4.3.Findings and Decisions#

Each completed prototype produces a short findings note recording: the charter reference, the measured or observed results against the pass/fail criteria, the conclusion (question answered yes / no / inconclusive), and the decision taken (concept confirmed, alternative concept selected, requirement adjustment proposed, or further feasibility work planned).

All findings are reviewed with internal stakeholders and – where relevant – the customer. The results are used to:

  • Finalize the implementation concept (updating the Concept Selection Table).
  • Refine or confirm technical requirements and budgets (Chapter 5).
  • Provide input to the System Requirements Specification (SRS).
  • Raise PRS change proposals where a requirement proves infeasible or impractical (Chapter 9).

Prototyping at this stage ensures that selected concepts are not only theoretically valid but practically achievable within the constraints of the project.

5.Technical Budgeting and Value Resolution#

5.1.Purpose#

The PRS authority test deliberately leaves certain values open: where the engineering team is the authority for a figure, the PRS states the functional need and defers the concrete value to this phase. Typical examples are achievable power consumption, internal and end-to-end timing budgets, physical dimensions and mass, environmental design margins beyond cited standards, and battery life. These values do not resolve themselves; this chapter defines the activity that resolves them. Without it, the PRS's clean separation between stating needs and determining values would leave a set of dangling unknowns at SRS time.

This activity is performed once the System Architecture exists and concept selection is substantially complete, and is refined as prototyping results arrive. Its outputs are a direct input to the SRS.

Relationship to the Device Architecture#

This activity is iterative and deliberately brackets the Device Architecture (Chapter 6); its two halves have opposite dependency directions:

  • Budget establishment is top-down and precedes the Device Architecture
    The system-level budgets and their per-module allocations are set from the PRS needs and the Business Case, and act as constraints on component selection and domain partitioning – a module's power allocation is decided before its components are chosen, not derived from them.
  • Value resolution is bottom-up and completes against the Device Architecture
    Concrete achievable figures – power consumption, mass, dimensions, unit cost – can only be finalized once components have been selected, because they are computed from component data, the preliminary BoM, and prototype measurements.

The two halves meet in the budget-versus-actual reconciliation of Step 4: where the bottom-up values fit the top-down allocations, the values are confirmed; where they do not, either the allocation is rebalanced within the system-level budget, the component choice is revisited, or – if the originating PRS need itself cannot be met – a change proposal is raised. This reconciliation typically iterates with the Device Architecture and the preliminary BoM (Chapter 11) until both converge.

5.2.Process#

Step 1Collect the deferred values#

Review the PRS systematically (in particular the non-functional requirements and any functional requirements expressed as needs without concrete figures) and compile the Deferred Value List: every value whose determination the PRS left to the engineering team. Each entry references the PRS requirement(s) it serves.

Step 2Establish system-level budgets#

For each quantitative resource that the deferred values draw on, establish a system-level budget consistent with the PRS need and the Business Case Background. Typical budgets include:

  • Power budget
    Total consumption target (e.g., derived from a battery-life need or an energy-cost positioning), allocated across functional modules with an explicit reserve.
  • Timing budget
    End-to-end latency targets for user-visible responses (anchored on PRS figures, including any cited perception thresholds), decomposed into per-module allocations.
  • Mass / volume / dimension budgets
    Where the PRS states handling, mounting, or portability needs.
  • Unit-cost budget
    The BoM target derived from the cost positioning in the Business Case Background, allocated across modules (coordinated with Chapter 11).

Each budget is documented as a table: total, per-module allocation, reserve, and the rationale for the split.

Step 3Resolve individual values#

For each entry in the Deferred Value List, determine the concrete value from the selected concept, the budget allocation, component data, analysis, or prototype results. Record the value, the determination method, and the supporting evidence. Note that where the determination depends on component data, this step can only be completed once the Device Architecture (Chapter 6) has progressed far enough to identify the components involved; until then, the budget allocation from Step 2 stands in as the working value.

Step 4Check against the originating need#

Verify that each resolved value actually satisfies the PRS functional need it serves. Where a bottom-up value exceeds its allocation but the need can still be met, rebalance the allocation within the system-level budget (drawing on the reserve or on under-consuming modules) or revisit the component choice. If a value cannot be made to satisfy the need within realistic concepts and budgets, this is a feasibility finding: raise a PRS change proposal through Chapter 9 rather than silently weakening the need.

Step 5Carry the values into the SRS#

Every resolved value becomes (part of) one or more system requirements, with traceability to both the originating PRS requirement and the budget or evidence that produced the value.

5.3.Output#

The result of the defined activity comprises:

  • The Deferred Value List with, for each entry: PRS reference, resolved value, determination method, evidence, and the SRS requirement(s) carrying it – or, for unresolved entries at phase end, an explicit carry-forward note (see Chapter 13).
  • The budget tables (power, timing, and others as applicable), which remain living engineering artifacts during detailed design: budgets are how the architecture's quantitative promises are policed as the design matures.

6.Device Architecture#

Based on the System Architecture, the selected implementation concepts, and the established budgets, the Device Architecture defines how each functional module will be realized in terms of the engineering domains. The per-module budget allocations (Chapter 5) act as constraints on component selection here; in return, the component data produced by the Device Architecture is what allows the deferred values of Chapter 5 to be finally resolved – the two activities iterate together until budgets and actuals converge.

6.1.Engineering Domains#

The Device Architecture allocates functionality across four domains:

  • Hardware
    Electronics: microcontrollers, sensors, displays, power circuitry.
  • Embedded software
    Firmware and applications executing on the hardware.
  • FPGA / programmable logic
    Applicable only when the product includes programmable logic; omitted otherwise.
  • Mechanical
    Enclosures, mounts, structural and motion-related elements; applicable where the product has a mechanical scope.

These four domains are referred to consistently throughout the SRA documentation. The division of functionality between domains is one of the most consequential architectural decisions of the entire development: it determines team structure, iteration speed (software changes are cheap, hardware respins are not), certification scope, and unit cost. The chosen partitioning, and the rationale for any functionality whose domain allocation was non-obvious, is documented explicitly.

6.2.Purpose#

The Device Architecture transitions from functional decomposition to physical implementation. It specifies:

  • The hardware components (e.g., microcontrollers, sensors, displays)
  • The software components (e.g., embedded firmware, applications)
  • The FPGA components, where applicable
  • The mechanical components (e.g., enclosures, mounts, connectors)
  • The physical interfaces between components (e.g., SPI, UART, Ethernet)

6.3.Representation#

The architecture is captured in two forms:

  • Device Architecture Diagram
    A graphical overview showing all physical components and their interconnections, including where software is executed and stored. Interfaces are annotated where known.
  • Mapping Table
    A table that maps each component to the functional module(s) it supports. This clarifies multi-use elements (e.g., a microcontroller participating in multiple functions) and, read in reverse, shows which components realize each functional module. Every functional module must be covered by at least one component; every component must support at least one module.

6.4.Distinction from System Architecture#

It is important to clearly distinguish the Device Architecture from the System Architecture. While the System Architecture defines what functions must exist and how they connect, the Device Architecture defines how and where those functions are implemented. Components may support multiple modules, and one module may span several components.

By establishing this physical view early, the Device Architecture supports:

  • Cross-disciplinary alignment (HW / SW / FPGA / ME)
  • Planning for integration and interfaces
  • Preparation for detailed design and test strategy
  • Construction of the preliminary BoM (Chapter 11)

7.Description of Functional Modules#

7.1.Purpose#

Following the definition of the Device Architecture, each functional module identified in the System Architecture is described in more detail to provide a clear understanding of how it will be technically realized. This bridges the gap between abstract functionality and concrete implementation – still at a system engineering level – by outlining how the components from the involved domains collaborate to fulfill each function.

7.2.Content#

For each functional module, a short technical description is provided that includes:

  • Role and Scope
    A brief summary of what the functional module does and which product requirements it supports (by PRS requirement ID).
  • Involved Components
    A list of the hardware, software, FPGA (if applicable), and mechanical components involved in implementing the functional module, based on the Device Architecture Mapping Table.
  • Interfaces
    The internal and external connections used by the functional module, identified by reference to the connection identifiers (IC-nn and EC-nn) defined in the System Architecture connection tables. Each referenced connection is annotated with any module-specific implementation notes that emerge from the selected concept and Device Architecture.
  • Selected Concept Summary
    A short recap of the chosen implementation concept (from the Concept Selection Table) and any relevant rationale or implications.
  • Budget Allocations
    The module's allocations from the technical budgets (Chapter 5) that constrain its design – e.g., its share of the power and timing budgets.

This information may be represented visually by redrawing the relevant portion of the Device Architecture to focus on the components and interfaces involved in the module.

7.3.Purpose in Documentation#

Describing each functional module serves multiple purposes:

  • Clarifies how each part of the system contributes to the overall functionality
  • Aids in assigning ownership during design and implementation
  • Provides context for writing specific technical requirements in the SRS
  • Supports reviews by showing how architectural and concept decisions map to actual functionality

By describing the functional modules in this way, the system design remains transparent and traceable, ensuring that each product requirement is addressed through well-understood technical elements.

8.Design Risk Analysis#

8.1.Purpose#

The Design Risk Analysis, typically performed in the form of a Design Failure Mode and Effects Analysis (DFMEA), is a structured and systematic evaluation of potential failure modes within the proposed system and device architecture.

The purpose of this activity is to:

  • Identify how each functional module or connection could fail
  • Assess the potential effects of such failures at system and user level
  • Evaluate the severity, likelihood of occurrence, and detectability of each failure mode
  • Define appropriate mitigation measures
  • Ensure that architectural weaknesses are addressed before detailed design begins

The Design Risk Analysis complements the SRS by focusing not only on intended functionality, but also on robustness under failure conditions. It introduces a failure-oriented perspective that challenges the architecture and strengthens the overall system design.

8.2.Position in the Process#

The Design Risk Analysis is performed after:

  • The System Architecture has been defined
  • Implementation concepts have been selected
  • The Device Architecture has been established
  • Functional modules have been described

At this stage, sufficient technical clarity exists to evaluate realistic failure modes, while the design remains flexible enough to allow architectural improvements.

The outcomes of the Design Risk Analysis provide direct input to:

  • The System Requirements Specification (SRS)
  • The Initial Product Test Plan
  • Development planning and estimation activities

By positioning the DFMEA at this point in the SRA phase, risks can be addressed while architectural changes are still feasible and cost-effective.

8.3.Scope of Analysis#

The analysis is performed at architecture and functional-module level. Typical elements considered include:

  • Functional modules and their responsibilities
  • Connections between modules and across the system boundary (data, control, power, and mechanical), enumerated by the IC-nn and EC-nn identifiers – the connection tables provide the systematic checklist that ensures no interface is skipped
  • Allocation of functionality across the engineering domains
  • Environmental and operational conditions
  • External dependencies (e.g., power supply, communication networks, user interaction)

The focus is on design-related risks. Manufacturing and process-related risks are addressed separately during the Industrialisation Analysis phase, if applicable.

The objective is to evaluate how the proposed design behaves under failure conditions and to ensure that no critical single points of failure or unmitigated risks remain in the architecture.

8.4.Rating Scales and Action Threshold#

Before the analysis begins, the project documents:

  • The rating scales used for Severity, Occurrence, and Detection (e.g., 1–10 scales per an applicable industry standard, or a simplified 1–5 scheme for smaller projects), with anchored definitions for each level so that ratings are reproducible across assessors.
  • The risk evaluation method – Risk Priority Number, criticality matrix, or an equivalent – and the action threshold: the rating at or above which a defined outcome (Section 8.7) is mandatory.

Defining the scales and threshold before rating begins is essential: without a pre-agreed threshold, "explicit risk acceptance" has no defensible basis, and ratings drift toward whatever avoids action. The chosen scheme may follow an applicable industry standard where the product domain demands it (e.g., automotive or medical).

8.5.Method#

For each functional module and critical connection, the following structured steps are performed:

  1. Identify the intended function.
  2. Identify potential failure modes (i.e., how the function could fail).
  3. Determine the effects of each failure mode at subsystem and system level.
  4. Assess the severity of the effect.
  5. Identify possible causes and assess the likelihood of occurrence.
  6. Evaluate the ability to detect the failure before it leads to impact.
  7. Assess the resulting risk level using the documented rating scheme.
  8. Define mitigation actions where the action threshold is met.

Mitigation actions may include:

  • Additional or refined system requirements
  • Architectural safeguards (e.g., redundancy, monitoring, fallback states)
  • Improved interface definitions
  • Additional verification or environmental testing
  • Refinement of non-functional requirements

The DFMEA is not merely a documentation exercise. It is an active design validation tool that challenges assumptions, identifies weaknesses, and drives measurable improvements in system robustness.

8.6.Security Threat Analysis for Connected Products#

A failure-mode analysis considers what can go wrong by accident; it does not consider an adversary. For any product with connectivity (wireless or wired network interfaces, web interfaces, remote update mechanisms, payment functions) or with assets worth protecting (credentials, personal data, payment data, safety functions), the Design Risk Analysis is complemented by a security threat analysis.

Security enters the process at two distinct levels, and the threat analysis is the second of them, not the first:

  • The PRS states the security needs
    Which assets must be protected, to what level, and which cybersecurity regulations apply (e.g., the EU Cyber Resilience Act, RED cybersecurity provisions, IEC 62443) are product-level concerns whose authority is the stakeholder or the regulator. Under the authority test, they are captured in the PRS as Security and Regulatory NFRs. These are requirements, not risks.
  • The threat analysis evaluates the chosen architecture against those needs
    It is the security counterpart of the DFMEA: where the DFMEA challenges the architecture against the functional requirements, the threat analysis challenges it against the security NFRs. The architecture is what creates the concrete attack surfaces – connections, interfaces, update paths – and an architectural choice can introduce a vulnerability that no product-level requirement anticipated. This is why the analysis belongs in the SRA and cannot be completed at PRS level.

The analysis itself is lightweight but explicit:

  • Take the PRS Security and Regulatory NFRs as input: they define the assets and the protection obligations the architecture must satisfy.
  • Identify the attack surfaces – which are largely already enumerated: the External Connection Table and Operational Connection Table list every path into the system.
  • For each surface, identify plausible threats (e.g., unauthorized access, interception, tampering, denial of service, malicious firmware) using a structured prompt-list such as STRIDE.
  • Rate and treat threats with the same discipline as DFMEA items: documented scales, an action threshold, and one of the defined outcomes of Section 8.7.

The findings produce system-level security requirements – authentication mechanisms, encryption of specific connections (by IC-nn/EC-nn identifier), secure-boot and signed-update mechanisms – that implement the PRS security NFRs, each traced both to the originating NFR and to its RISK-nn item, plus test-plan items such as penetration testing and fuzzing.

Where the analysis reveals a protectable asset or threat class that the PRS did not anticipate, this is a PRS gap: the missing product-level security need is fed back through a change proposal (Chapter 9) rather than silently patched at system level, keeping the authority boundary intact – the customer and regulator remain the authority for what must be protected; the engineering team is the authority for how.

If the product genuinely has no connectivity and no protectable assets – which should be evident from the absence of Security NFRs in the PRS – the omission of the threat analysis is recorded with a one-line justification rather than left implicit.

8.7.Output and Integration#

The results of the Design Risk Analysis are documented in a structured DFMEA table (and, where applicable, a threat analysis table) with stable item identifiers (e.g., RISK-nn). For each item at or above the action threshold, exactly one of the following outcomes shall be defined:

  • Risk mitigation implemented through updated architecture
  • Risk mitigation implemented through new or refined system requirements
  • Risk mitigation implemented through additional verification measures
  • Explicit risk acceptance, with documented rationale

All mitigation actions that affect product behaviour or constraints shall be reflected in the SRS, with traceability from each resulting requirement back to the originating RISK-nn item. The Initial Product Test Plan shall be updated where additional detection, monitoring, or validation activities are required. Where a mitigation changes the architecture, the System Architecture tables and diagram are updated per the maintenance rule (Section 2.5).

8.8.Role in Project Planning#

The Design Risk Analysis contributes directly to realistic and transparent project estimation by:

  • Making architectural complexity and uncertainty explicit
  • Identifying areas requiring prototyping or additional validation
  • Highlighting reliability-, safety-, or security-critical design elements
  • Supporting transparent communication of technical risk to the customer
  • Seeding the project risk register used in the Product Development Planning phase

By performing this structured risk evaluation during the SRA phase, the project reduces the likelihood of late-stage redesign, underestimated effort, or unforeseen reliability issues.

9.PRS Feedback and Change Control#

9.1.Purpose#

The PRS is the contractual baseline of what the product must do, and it is feasibility-unconstrained by design. The SRA is the phase where feasibility is actually evaluated – which means the SRA is also the phase where PRS adjustments are most likely to be needed. The PRA guidelines describe this feedback loop as intended and potentially recurring; this chapter defines how it operates, so that changes to a contractual baseline are made deliberately and transparently rather than informally.

9.2.Triggers#

A PRS change proposal is raised when SRA work shows that:

  • A requirement is technically infeasible within realistic concepts (typically a prototyping or concept-analysis finding).
  • A requirement is economically impractical – achievable, but at a cost that conflicts with the cost positioning in the Business Case Background (typically a pricing finding, Chapter 11).
  • A resolved value (Chapter 5) cannot satisfy the originating PRS need within the budgets.
  • The architecture or DFMEA work reveals a gap or contradiction in the PRS (e.g., two requirements that cannot be simultaneously satisfied, or behaviour the scenarios left unspecified that turns out to be architecturally significant).

9.3.The PRS Change Proposal#

Each proposal is a short, self-contained record containing:

  • A stable identifier (e.g., PCP-nn) and date.
  • The affected PRS requirement ID(s) and section(s).
  • The finding – what the SRA work established, with reference to the evidence (prototype findings note, trade-off study, BoM analysis, DFMEA item).
  • The proposed adjustment – the suggested new wording, value, or scope, and where useful one or two alternatives with their cost/feasibility implications.
  • The impact – consequences for other requirements, the architecture, the budgets, the schedule, and the business case.

9.4.Decision and Re-Baselining#

Change proposals are reviewed with the customer – individually for urgent findings, or batched at a phase review for the rest. The customer (or the designated stakeholder authority) decides: accept the adjustment, accept an alternative, reject it (keeping the original requirement, possibly with a re-scoped feasibility track), or descope the requirement.

Accepted changes are incorporated into a revised PRS version with an updated version identifier and a change log entry referencing the PCP-nn. The SRA artifacts (architecture tables, Concept Selection Table, budgets, SRS) are updated to the new baseline. PRS requirement IDs remain stable across revisions; superseded requirements are marked as such rather than deleted, preserving the trace history.

The loop may iterate several times within the SRA phase. What matters is that at phase end, the SRS traces to a single, identified PRS version, and every deviation from the original PRS is covered by a decided change proposal.

10.System Requirements Specification#

10.1.Purpose#

The System Requirements Specification (SRS) is the formal output of the SRA phase. It captures the complete set of technical system requirements that define how the product requirements from the PRS will be fulfilled.

These requirements are the foundation for detailed design, implementation, and verification. They translate functional intent into precise technical expectations that can be distributed across engineering disciplines and traced throughout the development lifecycle.

10.2.Sources of System Requirements#

System requirements originate from four sources, and each requirement records which source it derives from:

  1. PRS translation
    The technical decomposition of a product requirement into one or more system-level requirements.
  2. Resolved values and budgets (Chapter 5)
    Concrete figures for needs the PRS deferred to the engineering team, including per-module budget allocations that constrain detailed design.
  3. DFMEA and threat-analysis mitigations (Chapter 8)
    Requirements introduced to mitigate identified risks, traced to their RISK-nn items.
  4. Architectural and concept decisions
    Requirements that capture binding consequences of the selected architecture and concepts (e.g., interface specifications for the IC-nn/EC-nn connections).

Every system requirement must trace to at least one PRS requirement, directly or via its originating budget, risk item, or architectural element. A system requirement with no PRS ancestry indicates either scope creep or a missing PRS update – both of which must be resolved, the latter through Chapter 9.

10.3.Identification and Formulation#

System requirements are identified and formulated as follows:

  • ID scheme
    System requirements use the form REQ-SRS-nnn. Where the SRS is organized per module, a module-scoped form may be used instead (e.g., REQ-SRS-FM03-nnn); choose one scheme per project and apply it consistently. IDs remain stable for the product lifetime.
  • Formulation
    Each requirement is a declarative "shall" statement that is atomic (a single behaviour or constraint), unambiguous (one interpretation), and verifiable (testable by inspection, analysis, demonstration, or measurement). Behavioural requirements include their trigger or condition, following the same pattern as the PRS: "When [trigger / condition], the [module / system] shall [action / behaviour]." Quantitative requirements state value, unit, tolerance, and the conditions under which the value applies.
  • Categories
    Each requirement is assigned a category. The standard categories are: Functional, Interface (referencing IC-nn/EC-nn identifiers), Performance (timing, throughput, accuracy – typically carrying budget allocations), Electrical/Power, Environmental, Mechanical/Physical, Reliability/Safety, Security, and Regulatory. Categories may be omitted or added per product, mirroring the flexibility of the PRS NFR categories.

10.4.Requirement Metadata#

Each requirement entry includes:

  • The unique requirement ID.
  • The requirement statement.
  • The category.
  • Traceability – the associated PRS requirement ID(s), and where applicable the originating architecture element (FM-nn, IC-nn, EC-nn), budget, RISK-nn item, or PCP-nn change proposal.
  • The verification method indication – a brief statement of whether and how the requirement is testable (e.g., "thermal-chamber test", "EMC lab report", "inspection of label"). The detailed procedure is defined in the Initial Product Test Plan, but the SRS already establishes that a verification path exists.
  • The priority, inherited from the parent PRS requirement(s) or, where a system requirement serves multiple parents, the highest parent priority – with explicit justification for any override.

10.5.Format and Tooling#

Requirements may be listed directly in the SRS document and/or maintained in a requirements tracking database or tool. If both are used, consistency between the document and the database must be ensured – the source of truth is designated explicitly.

Requirements are typically organized by functional module (aligned with the System and Device Architecture), with cross-cutting requirements (environmental, regulatory, security) grouped by category. This structure aids readability, ownership allocation, and test planning.

10.6.Traceability and Review#

Establishing and maintaining traceability between the PRS and the SRS is essential. One product requirement may lead to multiple system requirements, and conversely, a single system requirement may support several product-level needs. A traceability check at SRS completion verifies both directions: every PRS requirement (of the current baseline) is covered by at least one system requirement or a decided change proposal, and every system requirement has PRS ancestry.

All requirements undergo internal review and customer review (where applicable) to validate:

  • Technical correctness
  • Feasibility (now substantiated by concept analysis, prototyping, and budgets – not asserted)
  • Alignment with the original product intent
  • Testability

Once approved, the SRS becomes a baselined document, traced to a single identified PRS version. Changes after this point follow a structured change control process.

11.Initial Product Pricing#

11.1.Purpose#

As part of evaluating the technical feasibility of the product, an initial cost estimate is developed. This is primarily based on a preliminary Bill of Materials (BoM), derived from the System and Device Architecture and early component selection.

The goal is not to finalize pricing, but to gain early insight into cost drivers, feasibility, and pricing sensitivity – and, critically, to test the estimate against the commercial assumptions the PRS was written under.

11.2.Process#

A concept-level BoM is constructed by identifying candidate components – typically COTS (Commercial Off-The-Shelf) – that could fulfill the hardware portion of each functional module. The selection process considers:

  • Availability and Lifecycle
    Key components should be backed by industrial supply contracts or long-term availability commitments to avoid End-of-Life (EoL) risks within the expected product lifetime stated in the PRS Business Case Background.
  • Regulatory Compliance
    All components must comply with relevant international regulations such as RoHS (Restriction of Hazardous Substances) and REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals), and must be compatible with the certification regions stated in the PRS.
  • Suitability and Feasibility
    Components must be technically and commercially appropriate for the intended use case, including form factor, power consumption (against the power budget of Chapter 5), performance, integration complexity, and any manufacturer-imposed restrictions on end use, application domain, or region of deployment.

11.3.Evaluation Against the Business Case#

The estimated unit cost is explicitly compared against the commercial assumptions in the PRS Business Case Background: the target production volume (component pricing is taken at that volume, not at an arbitrary quantity) and the cost positioning strategy. This comparison is one of the principal triggers of the PRS feedback loop: if the estimate is incompatible with the cost positioning, a PRS change proposal (Chapter 9) presents the options – relaxed requirements, alternative concepts, revised positioning – rather than leaving the conflict to surface during quotation.

11.4.Scope and Exclusions#

The estimate covers material cost only, unless explicitly extended. The following are excluded and stated as such in every estimate, so that the figure is never mistaken for a product price:

  • Non-recurring engineering (NRE) and development cost
  • Tooling and industrialisation cost (moulds, fixtures, test equipment)
  • Certification and compliance testing cost
  • Assembly, production test, packaging, and logistics cost
  • Licensing and royalties
  • Margins

Where any of these is already estimable and relevant to the customer decision, it may be reported separately – but never silently folded into the BoM figure.

11.5.Output#

The deliverable for this activity includes:

  • A concept BoM with estimated unit pricing at the PRS target volume
  • The comparison against the Business Case cost positioning, with conclusion
  • Notes on sourcing, regulatory compliance, and supply risk
  • A summary of assumptions and the explicit exclusion list of Section 11.4
  • Optional sensitivity analysis, showing how total cost varies with design choices or volumes

This pricing estimate is reviewed internally and – where appropriate – shared with the customer to align expectations before entering the detailed development phase.

12.Initial Product Test Plan#

12.1.Purpose#

With the Device Architecture defined and technical requirements outlined in the SRS, an Initial Product Test Plan is created to establish how the system will be verified. The plan ensures that both Product Requirements (from the PRS) and System Requirements (from the SRS) are verifiable and mapped to appropriate verification methods.

This test plan provides early alignment between development and quality assurance efforts, and it is used to communicate and agree on the verification approach with the customer.

12.2.Content#

The test plan is drafted as a separate document and includes:

  • Verification Strategies
    The approach to verifying each type of requirement (inspection, functional testing, simulation, analysis, demonstration), including the verification of budget compliance (Chapter 5) and of DFMEA/threat-analysis mitigations (Chapter 8) – e.g., fault-injection tests for fallback states, penetration testing for security requirements.
  • Test Tooling
    Any special test tools, equipment, or fixtures required for verification: hardware test setups, software tools or emulators, and custom test fixtures or interface boards.
  • Test Equipment Requirements
    Required lab instruments or external facilities (e.g., oscilloscopes, thermal chambers, EMC test benches, accredited certification labs). Long-lead or high-cost items are flagged for the planning phase.
  • Acceptance Criteria
    The pass/fail criteria for both product-level requirements (as defined in the PRS) and system-level requirements (as defined in the SRS).
  • Traceability
    Initial traceability between requirements and test activities, supporting future test planning and coverage analysis. Every SRS requirement's verification-method indication (Section 10.4) is consistent with the plan.

12.3.Process and Review#

The Initial Plan is used as follows:

  • The initial plan is discussed and agreed with the customer, especially for product-level validation and regulatory or contractual requirements.
  • It serves as an input for project planning, effort estimation, and identifying external test dependencies.
  • The test plan is initial: it is refined and expanded during development as more design detail becomes available.

By defining the verification approach early, the Initial Product Test Plan ensures that requirements are testable and that verification is considered proactively, not retrofitted after design.

13.Phase Completion and Exit Criteria#

The SRA phase is offered as a separate project with a go/no-go decision at its end. That decision needs a defined notion of "done". The phase is complete when the following exit criteria are satisfied; the closing review walks this checklist explicitly and records the result.

13.1.Coverage#

  • Every functional requirement of the current PRS baseline maps to at least one Functional Module, and every module traces back to PRS elements.
  • Every External Interface, System Actor, and boundary-crossing artifact from the PRS appears in the connection tables.
  • Every element of the PRS state model (states, choice-points, global transitions, History returns) has an owner in the State Model Ownership Table.

13.2.Decisions#

  • Every functional module has a Concept Selection Table entry with status Decided – or, for any remaining Pending entry, an explicit, customer-agreed plan (a separate feasibility track or a planned decision point early in development).
  • Every prototype charter has a findings note, and every finding has resulted in a decision.
  • The Deferred Value List is closed: every entry is either resolved into the SRS or explicitly carried forward with a documented plan and owner.

13.3.Risk#

  • The DFMEA (and threat analysis, where applicable) is complete over all modules and connections, and every item at or above the action threshold has exactly one defined outcome.
  • All resulting mitigations are reflected in the SRS, the architecture, or the test plan.

13.4.Baseline integrity#

  • All raised PRS change proposals are decided, and the PRS has been re-baselined accordingly; the SRS traces to that single PRS version.
  • The SRS is internally and (where applicable) customer-reviewed and baselined; bidirectional PRS↔SRS traceability is verified.
  • The architecture tables, diagram, Concept Selection Table, budgets, BoM, and test plan are mutually consistent with the baselined SRS.

13.5.Commercial#

  • The preliminary BoM estimate has been evaluated against the Business Case cost positioning, and any conflict has been resolved or escalated through a change proposal.
  • The deliverables required by the Product Development Planning phase (Section 1.3) are complete and handed over.

Open items that are deliberately carried into the next phase are permitted – but only as explicit, listed, owned carry-forwards in the closing review record, never as silent gaps. This preserves the central promise of the pre-development process: that each phase ends with a known, agreed state on which the customer can base an informed go/no-go decision.

1.Introduction#

The Industrialisation Requirements Analysis (IRA) phase is the third stage of the structured pre-development process, following the completion of the System Requirements Analysis (SRA) phase. It is a conditional phase: it is executed only when the product is intended to be produced and delivered in significant numbers and with a consistent quality level. For one-off systems, demonstrators, or very-low-volume specials, the phase is skipped and this decision is recorded explicitly in the project file, with a one-line justification, rather than left implicit.

When the product is intended for volume production, the industrialisation aspects must be analyzed before development planning and detailed design begin, for three reasons:

  • Manufacturability shapes the design
    Design-for-manufacturing, design-for-assembly, and design-for-test findings frequently require changes to the device architecture, the component selection, or even product-level requirements. Discovering these after detailed design has started leads to costly redesigns; discovering them now feeds them back through the established change-control loops while change is still cheap.
  • Industrialisation shapes the plan and the price
    Tooling, test equipment, validation builds, and ramp-up activities represent significant non-recurring cost and lead time, and assembly, test, and yield losses represent recurring cost on top of the material-only BoM estimate of the SRA. The Product Development Planning phase cannot produce a credible plan or estimate without these figures.
  • Industrialisation exposes hidden requirements
    Quality targets, traceability obligations, serviceability needs, packaging and logistics constraints, and regulatory production requirements are real product requirements that customer input rarely states explicitly. This phase surfaces them systematically.

Unlike the PRA and SRA, which are executed primarily between the customer and the system engineering team, the IRA involves a third party: the EMS (Electronics Manufacturing Services) partner, whose industrialisation engineers contribute process knowledge that neither the customer nor the design team possesses. Since the EMS partner is itself selected during this phase, the phase is organized to resolve this bootstrap dependency explicitly (see Section 1.4).

The primary deliverable of this phase is the New Product Introduction (NPI) Specification.

1.1.Inputs from Preceding Phases#

The IRA consumes the following inputs, all of which must be available in baselined form at phase start:

  • From the PRS: the Business Case Background (target volume, expected market lifetime, cost positioning, certification regions), the relevant non-functional requirements (quality, reliability, regulatory, environmental, serviceability), and the prioritization.
  • From the SRA: the System and Device Architecture, the Concept Selection Table, the preliminary BoM with its cost estimate and exclusion list, the DFMEA (and threat analysis where applicable), and the Initial Product Test Plan.

The SRA deliberately scoped two items out and handed them to this phase: the DFMEA addresses design risks and explicitly defers manufacturing and process-related risks to the IRA (Chapter 6 of these guidelines), and the Initial Product Pricing covers material cost only, explicitly excluding tooling, industrialisation, assembly, production test, packaging, and logistics cost (Chapter 8 of these guidelines).

1.2.Deliverables#

The IRA phase produces the following key deliverables:

  • Production Requirements Agreement
    The customer-agreed, high-level production requirements: quality and reliability targets, volumes and ramp-up profile, service and lifecycle expectations, and logistics and delivery conditions, recorded with stable identifiers.
  • EMS Evaluation Matrix and Selection Record
    A documented, criteria-based evaluation of candidate EMS partners and the rationale for the selection.
  • Manufacturing Concept Table
    For each manufacturing and assembly process, a documented evaluation of process options, classification, feasibility, risk, and rationale for the selected concept – the manufacturing counterpart of the SRA Concept Selection Table.
  • Process Validation Findings
    For critical or uncertain processes, validation runs governed by a process validation charter, with findings notes.
  • Production Test Strategy
    The staged production test approach (inspection, structural test, functional test, end-of-line, calibration), including coverage rationale, fixture and equipment needs, and the testability requirements fed back into the SRS.
  • Process Risk Analysis (PFMEA)
    A structured failure-mode evaluation of the planned manufacturing and assembly processes, with documented rating scales, mitigations, and stable item identifiers.
  • Key Component Risk Table and Initial Supply Chain Plan
    Identification of supply-critical components, their risk assessment, mitigation strategy, and the initial sourcing and logistics approach.
  • Industrialisation Cost Estimate
    Non-recurring (tooling, fixtures, test equipment, validation builds) and recurring (assembly, test, yield, packaging, logistics) cost estimates, evaluated against the Business Case cost positioning.
  • NPI Specification
    The consolidated, formal set of industrialisation requirements (REQ-NPI-nnn), traceable to the PRS, the SRS, and the analyses of this phase.
  • PRS / SRS Change Proposals
    Where applicable, formally documented proposals for adjusting the PRS or SRS based on industrialisation findings.

1.3.Relationship to the PRS and SRS#

The IRA has the same structural obligations toward the baselined PRS and SRS that the SRA had toward the PRS:

  • Manufacturability evaluation
    The PRS and SRS are written without asserting manufacturability at volume. This phase evaluates whether – and at what cost and yield – the specified product can actually be produced in the target volumes. Where it cannot, the finding is fed back through the change processes of Chapter 9, never silently absorbed.
  • Resolution of production-authority values
    Just as the PRS authority test deferred engineering values to the SRA, several values are deferred to this phase because their authority is the production domain: achievable yields, process capability figures, realistic ramp profiles, test takt times, tooling lead times. The IRA determines these values together with the EMS partner; they are never asked of the customer, and never guessed by the design team.
  • Coverage of production-relevant context
    Every Business Case assumption with production impact (volume, lifetime, cost positioning, certification regions) and every PRS NFR with production impact (quality, reliability, environmental, regulatory, serviceability) must be visibly consumed by an IRA activity. The completeness checks in Chapter 10 enforce this.

1.4.Stakeholders and the EMS Bootstrap#

This phase involves three parties: the customer (production requirements, quality and service expectations, commercial decisions), our system engineering and industrialisation team (translation between design and production, analysis ownership, document ownership), and the EMS partner (process capabilities, DFM/DFA/DFT expertise, cost and capacity data).

Because the EMS partner is selected during this phase, but its engineers are needed for this phase, the involvement is staged:

  1. The Production Requirements Agreement (Chapter 2) and the first pass of the Manufacturing Concept Analysis (Chapter 4) are performed without EMS involvement; they produce exactly the information an EMS candidate needs to be evaluated and to quote.
  2. The EMS Partner Selection (Chapter 3) then runs on that basis.
  3. The selected EMS partner's industrialisation engineers join the project, and the manufacturing concepts, test strategy, PFMEA, supply chain plan, and cost estimates are completed and refined with them.

This staging is deliberate: selecting an EMS partner before the production requirements are agreed makes the selection criteria arbitrary, while completing the manufacturing analysis before any EMS input makes it speculative.

1.5.Hand-off to Product Development Planning#

The IRA deliverables feed directly into the Product Development Planning and Estimation phase:

  • The NPI Specification defines work packages for industrialisation engineering: tooling design, fixture and test-equipment development, process validation, and pilot builds.
  • The Production Test Strategy identifies long-lead test equipment and fixture development that must appear on the critical path.
  • The PFMEA seeds the project risk register alongside the DFMEA, and its mitigations identify validation builds and process qualification activities to be budgeted.
  • The Industrialisation Cost Estimate completes the cost picture that the SRA's material-only estimate deliberately left open.
  • The EMS selection and supply chain plan define the external dependencies, contracts, and procurement lead times the plan must accommodate.

Keeping this downstream consumption in mind while producing each deliverable avoids rework during planning.

2.Production Requirements Agreement#

2.1.Objective#

The first activity of the phase is to reach an explicit agreement with the customer on the production requirements: the quality, volume, lifecycle, and delivery expectations the production setup must satisfy. These points are agreed at least at a high level in this phase; details are filled in later in the project, but every deferred detail is recorded as such rather than left open silently.

The agreement serves three purposes: it anchors all subsequent analyses of this phase (manufacturing concepts, test coverage, EMS selection, and supply chain strategy all depend on it), it forms the requirements input for the EMS request-for-quotation, and it surfaces customer expectations – particularly around quality and service – that the PRS typically does not state.

2.2.Topics#

Depending on the type of product, the agreement covers the following topic areas. Topics that genuinely do not apply are omitted with a one-line justification, mirroring the practice used elsewhere in the process.

  • Quality and reliability targets
    Outgoing quality level (e.g., maximum defect rate at delivery), early-life failure expectations, warranty period and the expected return rate it implies, and field reliability expectations. Where the PRS already contains reliability NFRs (e.g., MTBF), the production targets are checked for consistency with them – a production quality target that contradicts a PRS reliability requirement is a finding for Chapter 9, not a number to be quietly averaged.
  • Production volumes and ramp-up
    The target annual volume (taken from the Business Case Background and confirmed here), the expected ramp-up profile from pilot builds through volume production, seasonality or demand variability, and the planning horizon for volume commitments.
  • Service, support, and lifecycle
    The repair strategy (repair vs. replace; depot vs. field repair), spare-parts availability obligations and duration, the expected production lifetime and end-of-production commitments, and any refurbishment or upgrade expectations. These choices drive serviceability requirements (e.g., modular replaceable units, diagnostic access) that may not yet exist in the PRS or SRS – another Chapter 9 trigger.
  • Logistics and delivery
    Delivery model (to customer warehouse, drop-ship, regional hubs), packaging expectations, labelling, order lead-time expectations, and any service-level agreement on delivery performance.
  • Regulatory production obligations
    Production-side obligations that follow from the PRS regulatory NFRs: unit-level traceability and serialization, batch records, certificates of conformity, regulated production environments (e.g., medical device QMS requirements), and market-specific labelling. The PRS states which regulations apply; this agreement establishes what they demand from production.

2.3.Authority Considerations#

The authority test of the PRA applies here unchanged, with a third authority added:

  • The customer is the authority for volumes, ramp expectations, warranty and service commitments, delivery models, and quality positioning. Missing or unconfirmed values are flagged [TBD]/[TBC] and consolidated for resolution, exactly as in the PRS.
  • Standards and regulations are the authority for traceability, batch-record, and labelling obligations; these are stated with the source cited, not flagged.
  • The production domain (the EMS partner, once selected) is the authority for achievable yields, process capabilities, and test takt times. These are not asked of the customer and not flagged as customer-pending; they are recorded as production needs and resolved with the EMS partner later in the phase.

Asking the customer to confirm an achievable yield routes the decision to the party least equipped to make it – the same anti-pattern the PRA triage rules guard against.

2.4.The Production Requirements Table#

The agreed items are recorded in the Production Requirements Table, with the following specified for each item:

  • A stable identifier of the form PRA-nn (Production Requirement Agreement item).
  • The topic area (Quality / Volume / Lifecycle / Logistics / Regulatory).
  • The agreed statement, at the level of detail available in this phase.
  • The authority for the value (Customer / Standard / Production domain), with citation where a standard is the source.
  • The status: Agreed / [TBC] / [TBD] / Deferred-with-plan (for details deliberately filled in later, with a named owner and resolution point).

Each PRA-nn item is later formalized as one or more REQ-NPI requirements in the NPI Specification (Chapter 10), preserving traceability from the negotiated agreement to the formal requirement.

3.EMS Partner Selection#

3.1.Objective and Timing#

Depending on the type of product, the quality requirements, and the production volumes, a suitable EMS partner is selected. The selection is performed in two stages to resolve the bootstrap dependency described in Section 1.4:

  1. Shortlisting
    Can start as soon as the Production Requirements Agreement exists in draft: the volume class, quality class, regulatory regime, and product type are sufficient to reduce a long list to a shortlist.
  2. Selection
    Requires the first-pass manufacturing concepts (Chapter 4) and the preliminary BoM, because a meaningful request for quotation cannot be issued without them.

3.2.Selection Criteria#

The evaluation criteria are defined and weighted before any candidate is scored, mirroring the discipline of the SRA trade-off studies. Typical criteria include:

  • Technical capability
    The processes the product requires (from the first-pass Manufacturing Concept Table): e.g., fine-pitch assembly, conformal coating, box-build, cable assembly, calibration capability.
  • Quality system and certifications
    The certifications the product domain demands (e.g., ISO 9001 as baseline; ISO 13485 for medical; IATF 16949 for automotive), audit history, and demonstrated quality performance.
  • Capacity and scalability
    Headroom for the target volume and ramp profile, and flexibility for demand variability.
  • NPI competence
    The strength of the partner's own NPI process: DFM/DFA feedback quality, test development capability, prototype-to-volume transition track record.
  • Supply chain services
    Sourcing strength for the BoM at hand, component-engineering support, and willingness to operate the agreed sourcing model (Chapter 7).
  • Location and logistics
    Proximity to the customer's markets, import/export implications, and communication practicality (time zones, language, engineering access).
  • Commercial position
    Quoted unit cost and NRE at the target volume, cost-transparency, and contract terms.
  • Continuity
    Financial stability and strategic fit (is this product a meaningful account for the partner, or noise).

3.3.Process#

The selection follows a structured funnel; each step's output is recorded:

  1. Long list
    Candidates compiled from prior experience, customer preferences, and market research.
  2. RFI (Request for Information)
    Capability, certification, and capacity questions against the criteria; produces the shortlist (typically two to four candidates).
  3. Data package and RFQ
    Shortlisted candidates receive, under NDA, a defined data package: the preliminary BoM, the Device Architecture overview, the first-pass manufacturing concepts, the Production Requirements Table, and the target volumes. The RFQ requests unit cost at the PRS target volume, NRE breakdown, DFM feedback on the package, and proposed test approach. The DFM feedback requested here doubles as an evaluation instrument: the quality of a candidate's engineering response is itself scored.
  4. Evaluation
    Candidates are scored in the EMS Evaluation Matrix: one row per criterion, with weight, per-candidate score, and per-candidate evidence reference. The matrix is the auditable record of the decision.
  5. Audit
    For the leading candidate(s), an on-site or remote audit verifies the claims that matter most for this product (quality system, the critical processes, capacity). Audit findings are appended to the matrix.
  6. Selection and agreement
    The selection rationale is documented, reviewed with the customer (who may hold decision authority depending on the engagement model – this is established in the Production Requirements Agreement), and the engagement is formalized at least to the level needed for the partner's engineers to join the remaining IRA activities.

3.4.Customer-Imposed Partners#

Where the customer mandates a specific EMS partner (e.g., an existing relationship or in-house manufacturing), the selection funnel is not executed, but the evaluation is: the mandated partner is scored against the same criteria, and any criterion where the partner falls short of what the product needs is recorded as a project risk and fed into the PFMEA and the risk register. A mandated partner is a constraint, documented as such with rationale – exactly as the PRA treats customer-mandated implementation choices.

4.Manufacturing Concept Analysis#

4.1.Objective#

Using the Production Requirements Agreement and the SRA outputs, the preliminary manufacturing concepts are developed: how the product will be fabricated, assembled, calibrated, and packaged at the target volume and quality level. The activity mirrors the SRA Concept Analysis, but its subject is the process, not the product.

The analysis is performed in two passes, per the staging of Section 1.4: a first pass by the industrialisation team (sufficient for the EMS RFQ), and a completing pass together with the selected EMS partner's engineers.

4.2.Design Reviews: DFM, DFA, DFT#

The analysis opens with three structured reviews of the SRA design baseline:

  • Design for Manufacturing (DFM)
    Can the parts be fabricated reliably at volume? Reviewed against the Device Architecture and preliminary BoM: PCB technology and tolerances, component packages and their process implications, mechanical part producibility (moulding, machining, sheet metal), surface finishes, and coating needs.
  • Design for Assembly (DFA)
    Can the product be put together efficiently and repeatably? Assembly sequence feasibility, orientation and handling, fastening methods, cable and connector accessibility, and error-proofing opportunities (poka-yoke).
  • Design for Test (DFT)
    Can the product be verified economically in production? Test-point access, structural-test compatibility, programming and provisioning access, and diagnostic observability. DFT findings feed Chapter 5 directly.

Each review produces findings classified as: process choice (resolved within this chapter), design change needed (routed through Chapter 9), or accepted limitation (documented with rationale and, where relevant, a PFMEA entry).

4.3.The Manufacturing Concept Table#

Manufacturing concepts are recorded in the Manufacturing Concept Table, the defined artifact of this activity. The product's production flow is decomposed into manufacturing processes – fabrication steps, assembly stages, calibration steps, and packaging – each with a stable identifier of the form MP-nn (Manufacturing Process). For each process the table specifies:

  • The MP-id and process name.
  • The scope – what the process produces or accomplishes, and which Device Architecture elements it involves.
  • The classification, reusing the SRA scheme:
  • Trivial – a standard, well-understood process with established capability (e.g., conventional SMT assembly). Documented with confirmation that it meets the applicable requirements; minimal further effort.
  • Balanced – multiple viable process options with distinct trade-offs (e.g., conformal coating method, calibration approach, fastening technology). Resolved through a documented trade-off study against defined criteria (capability, cycle time, NRE, recurring cost, quality risk, EMS availability).
  • Exploratory – a critical manufacturing process: novel, near the limits of known capability, or with unproven yield for this product (e.g., an unusual bonding step, tight-tolerance optical alignment, a new potting process). Requires validation per Section 4.4.
  • The options considered and the selected concept (or "pending" while validation is open).
  • The rationale, with reference to the trade-off study where applicable.
  • The status – Decided / Pending Validation (with charter reference) / Pending Design Change (with change-proposal reference).

The classification serves the same planning purpose as in the SRA: exploratory processes flag validation effort and schedule risk, balanced processes flag engineering effort, and trivial processes flag routine work – making industrialisation effort drivers visible to the planning phase.

4.4.Critical Process Validation#

Processes classified as exploratory are validated before being relied upon, governed by a process validation charter – the direct counterpart of the SRA prototype charter, and subject to the same discipline:

  • The capability question, stated as a single decidable question (e.g., "Can the selected potting process achieve void-free encapsulation at the intended cycle time?").
  • Pass/fail criteria, objective and defined before the validation run – typically a capability or yield figure under stated conditions.
  • Scope and fidelity – what is deliberately not representative (e.g., hand assembly standing in for line assembly), so the conclusion is not over-extended.
  • Effort cap, with escalation rather than silent extension.

Validation runs are executed with the EMS partner where the capability under test is theirs. Each run produces a findings note (charter reference, results against criteria, conclusion, decision), and decisions update the Manufacturing Concept Table. Where a process cannot be validated within this phase's resources, it is escalated to the customer and either planned as a separate validation track or scheduled as an explicit early milestone in the development plan – never silently deferred.

4.5.Assembly, Calibration, and Packaging Concept#

Beyond individual processes, the analysis defines the overall production flow concept: the assembly sequence at the level of major stages, where calibration and configuration occur in the flow, where test stages sit (coordinated with Chapter 5), and the packaging and labelling concept including any customer- or regulation-driven requirements from the Production Requirements Table. The flow is documented as a simple production flow diagram referencing the MP-nn identifiers, giving the PFMEA (Chapter 6) its systematic checklist – the same role the connection tables play for the DFMEA.

5.Production Test Strategy#

5.1.Objective and Relation to the Initial Product Test Plan#

The SRA's Initial Product Test Plan addresses development verification: demonstrating, typically once, that the design meets its requirements. Production requires a different kind of testing – production verification: demonstrating, for every unit and at production takt, that the unit was built correctly. The Production Test Strategy defines this second kind, and is developed together with the EMS partner, whose test-engineering capability was a selection criterion for precisely this reason.

5.2.Test Stages#

The strategy defines which test stages exist in the production flow, what each covers, and why. Typical stages, applied as appropriate to the product:

  • Inspection
    Automated optical inspection (AOI), X-ray inspection for hidden joints, incoming inspection for critical components.
  • Structural test
    In-circuit test, flying probe, or boundary scan, verifying correct assembly independent of product function.
  • Programming and provisioning
    Firmware loading, configuration, key or certificate injection (coordinated with the security requirements of the SRS where applicable).
  • Functional test
    Exercising product functionality through its external interfaces, typically with a dedicated fixture.
  • Calibration
    Where the product requires per-unit calibration, integrated as a defined stage with its required references and equipment.
  • End-of-line test
    Final verification in the customer-visible configuration, including cosmetic inspection and packaging checks.
  • Screening
    Burn-in, run-in, or environmental stress screening, only where the reliability targets of the Production Requirements Agreement justify the cost.

5.3.Coverage, Cost, and Takt#

Test coverage is a trade-off, and the strategy makes it explicit rather than implicit: for each candidate defect class (from the PFMEA and from DFT findings), the strategy records at which stage it is detected – or that it is deliberately not screened, with rationale and an accepted-risk reference. Test time per stage is estimated against the takt time implied by the target volume; where a stage cannot fit the takt, the options (parallel stations, reduced coverage, design change) are evaluated as a balanced concept in the Manufacturing Concept Table.

5.4.Testability Requirements Feedback#

DFT findings that require design support – test points, test interfaces, self-test hooks, provisioning interfaces, fixture features – are fed back as system requirements through the change process of Chapter 9, so that they enter the SRS with traceability to this strategy. Testability that is not designed in during development cannot be retrofitted economically; this feedback loop is one of the principal reasons the IRA precedes development.

5.5.Test Equipment and Fixtures#

The strategy enumerates required test equipment and fixtures per stage, distinguishing standard equipment from custom development. Custom fixtures and test software are non-recurring engineering with significant lead time: each is flagged with a rough effort and lead-time class for the planning phase, and its cost is carried into the Industrialisation Cost Analysis (Chapter 8).

6.Process Risk Analysis (PFMEA)#

6.1.Purpose and Relation to the DFMEA#

The SRA's Design Risk Analysis (DFMEA) deliberately scoped out manufacturing and process-related risks and deferred them to this phase. The Process Failure Mode and Effects Analysis (PFMEA) closes that scope: it is a structured, systematic evaluation of how the planned production processes can fail and what those failures mean for product quality and delivery.

The division of labour is precise: the DFMEA asks "how can the design fail in use?"; the PFMEA asks "how can production build the design wrongly, and would we notice?". The two analyses are linked: DFMEA items whose causes lie in production variation (e.g., a solder-joint failure mode) reappear in the PFMEA from the process side, and the cross-references are recorded.

6.2.Scope and Method#

The PFMEA is performed over the production flow defined in Chapter 4, using the MP-nn identifiers as the systematic checklist that ensures no process step is skipped – the same role the IC-nn/EC-nn tables play for the DFMEA. For each process step, the structured steps mirror the DFMEA method: identify the intended process function; identify potential process failure modes; determine effects at product and customer level; assess severity; identify causes and occurrence; evaluate detection (which is where the Production Test Strategy is stress-tested – a failure mode with no detecting stage is a finding); compute the risk level; and define actions where the threshold is met.

As with the DFMEA, the rating scales and action threshold are documented before rating begins, following an applicable industry standard where the product domain demands it. Without a pre-agreed threshold, ratings drift toward whatever avoids action.

6.3.Output and Integration#

Results are documented in a structured PFMEA table with stable identifiers of the form PRISK-nn. For each item at or above the action threshold, exactly one outcome is defined:

  • Mitigation through a process change (updating the Manufacturing Concept Table).
  • Mitigation through an added or modified test stage (updating the Production Test Strategy).
  • Mitigation through a design change (routed through Chapter 9 as a PRS or SRS change proposal).
  • Mitigation through a new NPI requirement (e.g., a process control, an incoming-inspection requirement), carried into the NPI Specification with traceability to the PRISK-nn item.
  • Explicit risk acceptance, with documented rationale.

The PFMEA items at or above threshold, together with their dispositions, seed the process control plan that will be elaborated during industrialisation execution, and feed the project risk register used in the planning phase.

7.Supply Chain Analysis#

7.1.Objective#

To prevent supply problems with key components from surfacing during development or – worse – during production ramp, an initial supply chain plan is constructed. The analysis builds on the preliminary BoM from the SRA, which already screened components for lifecycle and regulatory compliance; this phase deepens that screening into a risk-managed sourcing strategy at the target volume.

7.2.Key Component Identification#

From the preliminary BoM, key components are identified: components whose supply failure would halt production or force redesign. Identification criteria include:

  • Single-source components with no qualified alternative.
  • Long-lead components relative to the planning horizon.
  • Lifecycle risk – components nearing end-of-life within the production lifetime committed in the Production Requirements Agreement.
  • Allocation risk – components in markets with known shortage dynamics.
  • Cost drivers – components dominating the BoM cost, whose price volatility threatens the cost positioning.
  • Regulatory exposure – components with compliance dependencies (e.g., RoHS exemptions with sunset dates, export-control constraints, conflict-minerals reporting).

7.3.The Key Component Risk Table#

Each key component is recorded in the Key Component Risk Table with:

  • A stable identifier of the form KC-nn (Key Component).
  • The component and its BoM reference and the functional module(s) it serves.
  • The risk class(es) from the criteria above.
  • The assessment – likelihood and impact, with evidence (manufacturer lifecycle statements, distributor data, market intelligence).
  • The mitigation strategy – typically one or more of: qualifying a second source (with the qualification effort flagged for the development plan), designing for footprint/alternative compatibility (fed back as an SRS requirement through Chapter 9), a lifetime or buffer buy strategy, a supply agreement with availability commitments, or redesign away from the component (a Chapter 9 trigger).
  • The owner of the mitigation (our team, the EMS partner, or the customer) and its status.

7.4.Sourcing Model and Logistics Outline#

The plan records the agreed sourcing model – which party (EMS partner, customer, or the engineering organisation) owns procurement and supplier relationships for which parts of the BoM (full turnkey, consigned components, or hybrid) – and the consequences for liability, buffer ownership, and price transparency. It also outlines the logistics concept consistent with the delivery expectations of the Production Requirements Agreement: where finished goods are buffered, who owns finished-goods inventory, and the order-to-delivery flow.

The result at this stage is an initial plan: sufficient to expose risks, assign mitigations, and ground the planning phase – not a full supply chain design, which belongs to industrialisation execution.

8.Industrialisation Cost Analysis#

8.1.Purpose#

The SRA's Initial Product Pricing was explicitly material cost only, with tooling, industrialisation, assembly, test, packaging, and logistics cost excluded and listed as such. This phase resolves those exclusions, completing the cost picture the customer needs for the go/no-go decision into development.

8.2.Content#

The estimate, constructed with EMS partner input, distinguishes:

  • Non-recurring cost (NRE)
    Tooling (moulds, dies, stencils), assembly and test fixtures, custom test equipment and test software development (from Chapter 5), process validation runs (from Chapter 4), pilot builds, and certification-related production audits.
  • Recurring cost adders
    Assembly labour and machine time, test time per unit (from the takt analysis), expected yield losses (informed by the PFMEA and validation findings), packaging materials, and logistics cost per unit under the agreed delivery model.

Together with the SRA material estimate, this yields a landed unit cost indication at the target volume, plus the NRE investment profile. Assumptions and remaining exclusions (e.g., margins, duties where not yet determinable) are stated explicitly in every estimate, so the figure is never mistaken for a final price.

8.3.Evaluation Against the Business Case#

The completed cost picture is compared against the cost positioning in the PRS Business Case Background – the same evaluation the SRA performed for material cost, now with the full cost stack. An incompatibility is a principal trigger of the feedback loop: a change proposal (Chapter 9) presents the options – relaxed requirements, alternative manufacturing concepts, revised volumes or positioning – rather than leaving the conflict to surface during quotation or, worse, after tooling investment.

9.Requirements Feedback and Change Control#

9.1.Purpose#

The PRS and SRS are baselined documents; industrialisation findings that affect them are processed through structured change control, never informally. This chapter routes IRA findings to the correct baseline.

9.2.Triggers#

A change proposal is raised when IRA work shows that:

  • A DFM/DFA/DFT finding requires a design change (component change, layout provision, test point, mechanical change).
  • A quality or cost target is unachievable with realistic processes at the target volume (a validation, PFMEA, or cost-analysis finding).
  • A supply chain mitigation requires design support (alternative-component compatibility, footprint flexibility) or component replacement.
  • The Production Requirements Agreement exposes a gap in the PRS – a serviceability, traceability, packaging, or lifecycle need the PRS never captured.
  • A mandated constraint (e.g., a customer-imposed EMS partner or component) conflicts with an existing requirement.

9.3.Routing and Format#

Findings are routed by the authority of the affected baseline:

  • Product-level impact (what the product must do, its quality positioning, its business case) → a PRS Change Proposal (PCP-nn), using the format and decision process defined in the SRA guidelines unchanged. The customer decides.
  • System-level impact (how the product realizes its requirements: components, interfaces, testability provisions, design margins) → an SRS Change Request, with a stable identifier of the form SCR-nn and the same record structure as a PCP (affected requirement IDs, finding with evidence reference, proposed adjustment with alternatives, impact). SCRs are decided through the SRS change-control process established at SRS baselining, with customer involvement where the change has cost, schedule, or behavioural impact.

A single finding may produce both (e.g., an unachievable quality target may relax a PRS NFR and change an SRS design provision); the records cross-reference each other.

9.4.Re-Baselining#

Accepted changes produce revised PRS/SRS versions with updated version identifiers and change-log entries, exactly as in the SRA. IRA artifacts (Manufacturing Concept Table, test strategy, PFMEA, cost estimate, NPI Specification) are updated to the new baselines. At phase end, the NPI Specification traces to a single identified PRS version and a single identified SRS version, and every deviation from the phase-start baselines is covered by a decided PCP or SCR.

10.NPI Specification#

10.1.Purpose#

The NPI Specification is the formal output of the IRA phase. It consolidates the production requirements, the selected manufacturing and test concepts, the risk analyses, and the supply chain plan into a single specification that defines what the industrialisation of the product must achieve – the baseline against which industrialisation execution is later planned, performed, and verified.

10.2.Requirements Formulation#

The core of the document is the set of NPI requirements:

  • ID scheme
    Requirements use the form REQ-NPI-nnn; IDs remain stable for the product lifetime.
  • Formulation
    Declarative "shall" statements that are atomic, unambiguous, and verifiable, following the same formulation rules as the PRS and SRS. Quantitative requirements state value, unit, tolerance, and conditions. Where a value's authority is the production domain and it is resolved by EMS data or validation results, the evidence is referenced; where a value remains unresolved at phase end, it is carried forward explicitly per Chapter 11.
  • Categories
    The standard categories are: Quality (yield, outgoing quality, process capability), Volume and Capacity, Process (mandated process controls, validation obligations), Production Test (stage coverage, takt, fixture obligations), Traceability and Serialization, Packaging and Logistics, Service and Repair, and Supply Chain (second-source obligations, buffer policies). Categories may be omitted or added per product, mirroring the flexibility of the PRS NFR categories.

10.3.Requirement Metadata and Traceability#

Each requirement entry includes the ID, statement, category, traceability (the originating PRA-nn item, PRS/SRS requirement, MP-nn process, PRISK-nn item, or KC-nn component), the verification method indication (e.g., "process capability study", "pilot-build yield report", "packaging drop test"), and the priority, inherited from its sources with justification for any override.

A traceability check at completion verifies both directions: every PRA-nn item, every above-threshold PRISK-nn disposition that produced a requirement, and every KC-nn mitigation with requirement impact is covered by at least one REQ-NPI requirement – and every REQ-NPI requirement has ancestry in the agreement, the analyses, or the PRS/SRS. An NPI requirement with no ancestry indicates scope creep or a missing update, both of which must be resolved.

10.4.Document Structure#

The NPI Specification is structured as follows:

# Chapter Content
1 Introduction Purpose, scope, applicability decision, referenced PRS and SRS versions.
2 Document Conventions ID schemes (PRA-nn, MP-nn, PRISK-nn, KC-nn, REQ-NPI-nnn); "shall" conventions; [TBD]/[TBC] markers and the authority test as extended in this phase.
3 Production Requirements Agreement The Production Requirements Table with agreed quality, volume, lifecycle, logistics, and regulatory items.
4 EMS Partner The selection record: criteria, evaluation matrix summary, audit findings, selection rationale (or mandated-partner evaluation).
5 Manufacturing Concept Production flow diagram; Manufacturing Concept Table; process validation charters and findings notes.
6 Production Test Strategy Test stages, coverage rationale, takt analysis, equipment and fixture list with lead-time flags.
7 Process Risk Analysis PFMEA table with rating scheme, threshold, dispositions, and control-plan seeds.
8 Supply Chain Plan Key Component Risk Table; sourcing model; logistics outline.
9 Industrialisation Cost NRE and recurring cost estimates; landed unit cost indication; Business Case comparison; assumptions and exclusions.
10 NPI Requirements The REQ-NPI-nnn requirements, organized by category, with full metadata.
11 Reference Materials Glossary; referenced standards; source documents (PRS/SRS versions, EMS data, validation reports); decided PCP/SCR list.
A…Z Appendices Open Items Summary of genuine stakeholder-authority [TBD]/[TBC] items; extended evaluation and validation data.

10.5.Review and Baselining#

The NPI Specification undergoes internal review, EMS partner review (for the chapters that bind the partner), and customer review. Once approved, it becomes a baselined document; subsequent changes follow structured change control. Together with the Product Development Plan of the next phase, it forms the basis for the industrialisation work packages and the contractual production agreements.

11.Phase Completion and Exit Criteria#

The IRA phase is offered as a separately purchasable project with a go/no-go decision at its end. The phase is complete when the following exit criteria are satisfied; the closing review walks this checklist explicitly and records the result.

11.1.Coverage#

  • Every Business Case assumption and PRS NFR with production impact is consumed by a Production Requirements Table item or an explicit not-applicable note.
  • The production flow covers the complete product (every Device Architecture element is produced, assembled, tested, and packaged by some MP-nn step).
  • Every PRA-nn item is either formalized in a REQ-NPI requirement or explicitly deferred with owner and plan.

11.2.Decisions#

  • The EMS partner is selected (or the mandated partner evaluated), with the evaluation matrix and rationale recorded.
  • Every Manufacturing Concept Table entry has status Decided – or, for any remaining Pending entry, an explicit, customer-agreed plan (a separate validation track or a planned early decision point in development).
  • Every process validation charter has a findings note, and every finding has resulted in a decision.

11.3.Risk#

  • The PFMEA is complete over all MP-nn steps, and every item at or above the action threshold has exactly one defined outcome.
  • Every identified defect class is either covered by a test stage or explicitly accepted with rationale.
  • Every KC-nn component has an assigned mitigation with owner and status.

11.4.Baseline Integrity#

  • All raised PCPs and SCRs are decided, and the PRS and SRS have been re-baselined accordingly; the NPI Specification traces to those single versions.
  • The NPI Specification is reviewed (internal, EMS, customer) and baselined; traceability is verified in both directions per Section 10.3.
  • The Manufacturing Concept Table, test strategy, PFMEA, supply chain plan, and cost estimate are mutually consistent with the baselined NPI Specification.

11.5.Commercial#

  • The full cost picture (material + industrialisation NRE + recurring adders) has been evaluated against the Business Case cost positioning, and any conflict has been resolved or escalated through a change proposal.
  • The deliverables required by the Product Development Planning phase (Section 1.5) are complete and handed over.

Open items deliberately carried into the next phase are permitted – but only as explicit, listed, owned carry-forwards in the closing review record, never as silent gaps. This preserves the central promise of the pre-development process: that each phase ends with a known, agreed state on which the customer can base an informed go/no-go decision.

1.Introduction#

The Product Development Planning and Estimation (PDP) phase is the fourth and final stage of the structured pre-development process, following the completion of the System Requirements Analysis (SRA) phase and — where the product is intended for volume production — the Industrialisation Requirements Analysis (IRA) phase. Where the IRA was skipped, the recorded skip decision and its justification are inputs to this phase, and the industrialisation-related planning elements described in these guidelines are omitted with the same one-line justification practice used elsewhere in the process.

The preceding phases were deliberately constructed to make this phase possible. The PRA established what the product must do, the SRA established how it can be realized and at what material cost, and the IRA established how it can be produced and at what industrialisation cost. The PDP phase consolidates these baselines into two tightly coupled outputs: a Product Development Plan that defines how the development will be executed, and a project estimation of effort, cost, and schedule that is credible because it is grounded — work package by work package — in the artifacts of the preceding phases.

The phase exists as a distinct activity, rather than as an administrative wrap-up, for three reasons:

  • Estimation quality is decided here, not earlier
    The preceding phases produced exactly the artifacts that make a defensible bottom-up estimate possible: a functional decomposition with classified concepts, resolved technical budgets, a priced BoM, risk analyses with dispositions, and an industrialisation cost picture. An estimate produced without systematically consuming these artifacts wastes that investment and reverts to guesswork. This phase defines the consumption explicitly, so that every estimate line can answer the question "what is this number based on?".
  • Planning decisions are commitments
    Tooling release, lifetime component buys, certification submissions, EMS contracts, and design freezes are points of no — or expensive — return. Placing decision gates deliberately before each irreversible commitment, rather than discovering them mid-development, is a planning activity that cannot be deferred to execution.
  • The plan is the contract basis
    The pre-development process is explicitly positioned as part of the sales and early engagement process. The Product Development Plan and its estimation form the basis for the contractual agreement covering development execution. A plan that is not traceable to the agreed baselines is not a defensible contract basis.

The primary deliverable of this phase is the Product Development Plan (PDP), together with the project estimation it carries.

1.1.Inputs from Preceding Phases#

The PDP consumes the following inputs, all of which must be available in baselined form at phase start:

  • From the PRA: the baselined PRS at its final pre-development version, in particular the Business Case Background (target volume, expected market lifetime, cost positioning, certification regions, and any stated time-to-market expectations), the prioritization (Essential through Future), and the non-functional requirements with certification impact.
  • From the SRA: the System and Device Architecture with the Functional Module Table, the Concept Selection Table with its Trivial / Balanced / Exploratory classifications, the technical budgets and the Deferred Value List with any explicit carry-forwards, the DFMEA (and threat analysis where applicable) with all dispositions, the preliminary BoM with its cost estimate and exclusion list, and the Initial Product Test Plan with its flagged long-lead and high-cost test equipment.
  • From the IRA (where executed): the baselined NPI Specification, the EMS selection record and the formalized engagement, the Manufacturing Concept Table with any customer-agreed pending entries, the Production Test Strategy with its equipment and fixture list and lead-time flags, the PFMEA with dispositions, the Key Component Risk Table with assigned mitigations, the Industrialisation Cost Estimate, and the closing-review record with its explicit carry-forwards.
  • From all phases: the closing-review records, whose explicit carry-forward lists are a first-class input to this phase (see Chapter 2).

The earlier guidelines each contain a "Hand-off to Product Development Planning" section describing how their deliverables are constructed for consumption here. These guidelines are the receiving side of those hand-offs: each consuming activity below names the artifacts it consumes, and the completeness checks in Chapter 12 verify that nothing handed over was dropped.

1.2.Deliverables#

The PDP phase produces the following key deliverables:

  • Planning Baseline Record and Carry-Forward Register
    The verified set of baseline versions (PRS, SRS, NPI Specification) the plan is built on, and the consolidated register of all items explicitly carried forward from the preceding phases, each with an owner and a scheduled resolution point in the plan.
  • Work Breakdown Structure (WBS)
    The complete decomposition of the development and industrialisation work into work packages with stable identifiers, scope, deliverables, traceability, and completion criteria.
  • Integration, Milestone, and Decision Gate Plan
    The chosen development lifecycle, the sample and integration stages, the milestone list, and the decision gates placed before irreversible commitments — each gate with entry criteria, decision authority, and fallback options.
  • Effort and Cost Estimate
    A bottom-up, work-package-level estimate of development effort and cost, consolidated with material cost, industrialisation NRE, certification, licensing, and procurement cost into the full project cost picture, with a documented basis of estimate, explicit contingency, and a stated accuracy class.
  • Project Schedule
    The dependency network, the critical path including long-lead items, the alignment with EMS and supplier lead times, and explicitly placed schedule buffers.
  • Resource and Competency Plan
    The required competencies per engineering domain, the staffing profile over time, identified capacity constraints and key-person dependencies, and the use of external resources.
  • Supplier and EMS Alignment Plan
    The contracts and agreements to be formalized, the procurement actions with lead times, and the scheduled execution of the supply chain mitigations defined in the IRA.
  • Consolidated Project Risk Register
    A single register seeded from the DFMEA, threat analysis, PFMEA, Key Component Risk Table, and carry-forwards, extended with planning-phase risks, with owners, mitigations, and the explicit link between risk exposure and contingency.
  • Verification, Validation, and Certification Plan
    The expansion of the Initial Product Test Plan and the Production Test Strategy into scheduled, resourced verification activities and a certification path with submission milestones.
  • Product Development Plan
    The consolidated planning document (Chapter 12) that carries all of the above and forms the basis for the contractual agreement and the customer's go/no-go decision into development.
  • PRS / SRS / NPI Change Proposals
    Where applicable, formally documented proposals for adjusting the baselines based on planning findings — most commonly a conflict between the full cost or schedule picture and the Business Case.

1.3.Relationship to the Baselined PRS, SRS, and NPI Specification#

The PDP has the same structural obligations toward the baselines that each preceding phase had toward its predecessors:

  • Complete coverage
    Every requirement of the current PRS, SRS, and NPI Specification baselines within the agreed release scope must be visibly carried by the plan: realized by a development work package, verified by a planned verification activity, or explicitly deferred to a later release by a customer-agreed scope decision. The completeness checks in Chapter 12 enforce this in both directions — a work package with no requirement ancestry indicates scope creep, exactly as an untraceable requirement did in the earlier phases.
  • Resolution of planning-authority values
    The authority test of the PRA applies here with the final extension of the authority set. The project organisation (our engineering and project management team) is the authority for effort estimates, internal schedule logic, and resource allocations — these are never asked of the customer and never taken from a supplier. Suppliers and the EMS partner are the authority for quoted lead times, NRE quotations, and capacity commitments — these are obtained as quotations or commitments, not estimated internally where a quotation is obtainable. The customer is the authority for budget ceilings, market-window constraints, release scope decisions, and the acceptance of risk-driven options. Routing any of these values to the wrong party repeats the anti-pattern the earlier phases guard against: asking the customer to confirm an effort estimate, or estimating a tooling lead time the EMS partner could simply quote, routes the decision to the party least equipped to make it.
  • Feasibility of the plan itself
    Just as the SRA evaluated technical feasibility and the IRA evaluated manufacturability, the PDP evaluates executability: whether the specified product can actually be developed within the commercial and temporal expectations of the Business Case. Where it cannot, the finding is fed back through the change processes of Chapter 11, never silently absorbed into an optimistic plan.

1.4.Stakeholders#

This phase involves the customer (budget and schedule expectations, release scope decisions, gate authority agreements, contractual negotiation), the system engineering and project management team (plan ownership, estimation, document ownership), the EMS partner where selected (industrialisation work package definition, NRE and lead-time quotations, capacity commitments), and key suppliers identified in the supply chain analysis (lead-time and availability commitments for key components).

Unlike the IRA, this phase has no bootstrap dependency: all parties are known at phase start. The phase is, however, the point where informal engagements become contractual ones — the EMS engagement formalized "at least to the level needed" during the IRA is developed here into the production-related agreements the plan depends on.

1.5.Hand-off to Development Execution#

The PDP deliverables feed directly into development execution:

  • The WBS defines the work packages against which execution is organized, progressed, and reported.
  • The milestones and decision gates define the governance rhythm of the project and the points at which the customer exercises decision authority.
  • The consolidated risk register becomes the living risk management instrument of the project, reviewed at every gate.
  • The estimate and its basis become the reference against which actuals are tracked, and the basis-of-estimate records make deviations diagnosable rather than mysterious.
  • The baselined Product Development Plan, together with the NPI Specification where applicable, forms the basis for the development contract and the production-related agreements.

The pre-development process ends with this hand-off. Its central promise — that each phase ends with a known, agreed state on which the customer can base an informed go/no-go decision — is fulfilled for the last time here, at the decision that matters most: the commitment to development.

2.Planning Baseline Consolidation#

2.1.Objective#

Before any planning content is produced, the inputs are consolidated and verified. Planning against stale, inconsistent, or silently incomplete baselines produces a plan whose traceability is broken from the start; this short activity prevents that.

2.2.Input Verification#

The following is verified and recorded in the Planning Baseline Record:

  • The exact versions of the PRS, SRS, and NPI Specification (where applicable) the plan is built on. Each must be the baselined version produced by the closing review of its phase, with all raised change proposals decided and incorporated. The plan traces to these single identified versions, exactly as the SRS traces to a single PRS version.
  • The mutual consistency of the supporting artifacts with their baselines: the Concept Selection Table, budgets, BoM, DFMEA, Manufacturing Concept Table, PFMEA, test strategy, and cost estimates must reflect the final baselines, not an intermediate state.
  • The applicability decision for the IRA: either the IRA deliverables are present and baselined, or the recorded skip decision is present and the industrialisation planning elements of these guidelines are marked not applicable with reference to it.

Any discrepancy found here is resolved before planning proceeds — typically by completing a missed artifact update — and is never worked around inside the plan.

2.3.The Carry-Forward Register#

The closing reviews of the SRA and IRA explicitly permit open items to be carried into this phase — but only as explicit, listed, owned carry-forwards. This activity is where that permission is honoured and closed out: every carry-forward recorded in a preceding closing review is consolidated into the Carry-Forward Register, with the following specified for each item:

  • A stable identifier of the form CF-nn (Carry-Forward).
  • The origin — the closing-review record and the original item (e.g., a Deferred Value List entry, a Concept Selection Table entry with status Pending, a Manufacturing Concept Table entry with a customer-agreed validation track, a [TBD]/[TBC] item from an Open Items Summary).
  • The owner.
  • The resolution activity — the work package and milestone in this plan where the item is resolved. Carried-forward feasibility and validation work is scheduled early, as the explicit early milestones the preceding guidelines promised; an unresolved exploratory concept scheduled late in the plan defeats the purpose of having classified it.
  • The decision impact — which downstream work packages or gates depend on the resolution, so that the schedule consequences of a negative outcome are visible in advance.

The governing rule: a carry-forward without a scheduled resolution point is a planning gap. The register is reviewed at the phase-end closing review, and the completeness check in Chapter 12 verifies that every carry-forward from every preceding closing review appears in it.

2.4.Release Scope Confirmation#

The PRS prioritization (Essential, Secondary, Nice-to-have, Emerging, Future) was defined to support exactly this moment: the definition of release scope. Together with the customer, the scope of the development being planned is confirmed:

  • Which priority levels — and, where the cut is finer, which individual use cases and requirements — are in the scope of the first release (typically Essential and Secondary, per the PRA guidelines).
  • Which items are explicitly planned for later releases, and whether the plan must accommodate them architecturally (Emerging and Future items typically require no planning beyond awareness).
  • Whether the dependency consistency of the scope cut holds: no in-scope item may depend on an out-of-scope item, mirroring the dependency consistency check of the PRA prioritization chapter.

Release scope is a customer-authority decision. It is recorded explicitly in the plan, and every requirement excluded from the planned scope is excluded by this recorded decision — never by silently failing to plan for it.

3.Work Breakdown Structure#

3.1.Objective#

The development and industrialisation work is decomposed into work packages: bounded units of work with a defined scope, defined deliverables, a single owner, and verifiable completion criteria. The WBS is the backbone of the plan — estimation, scheduling, resource planning, and progress tracking all operate on it. The activity mirrors the architectural decomposition of the SRA: where the SRA decomposed the product, this chapter decomposes the work.

3.2.Derivation#

The WBS is not invented; it is derived from the preceding artifacts, in four groups:

  • Module development work packages
    Derived from the Functional Module Table, which the SRA guidelines explicitly constructed as a natural work breakdown structure. Each functional module yields one or more work packages, partitioned along the engineering domains of the Device Architecture (hardware, embedded software, FPGA where applicable, mechanical) where the domains imply different owners, skills, or iteration rhythms. The Concept Selection Table classification of each module is inherited by its work packages and drives their estimation treatment (Chapter 5).
  • Cross-cutting development work packages
    Work that no single module owns: system integration, system-level verification against the SRS and PRS, certification and compliance testing, requirements and configuration management, project management, and quality assurance. These are enumerated deliberately, because cross-cutting work is the classic source of underestimation: it appears in no module and is therefore forgotten by purely module-driven breakdowns.
  • Industrialisation work packages — derived from the NPI Specification, which the IRA guidelines explicitly constructed to define them: tooling design and procurement, fixture and test-equipment development (from the Production Test Strategy equipment list), production test software development, process validation tracks, pilot builds, supply chain mitigations with requirement impact (e.g., second-source qualification from the Key Component Risk Table), and production documentation. Omitted in full, with reference to the skip decision, where the IRA was not executed.
  • Carry-forward resolution work packages — derived from the Carry-Forward Register (Chapter 2), covering the early feasibility, validation, and decision work the preceding phases deferred.

3.3.The Work Package Table#

The WBS is recorded in the Work Package Table, the defined artifact of this activity, with the following specified for each work package:

  • A stable identifier of the form WP-nn (Work Package).
  • The name and a one-paragraph scope statement — what the work package produces, and explicitly what it does not produce where the boundary with an adjacent package could be misread.
  • The deliverables — the concrete outputs (design documents, implemented and verified modules, fixtures, reports).
  • The traceability — the originating elements: FM-nn modules, REQ-SRS / REQ-PRS / REQ-NPI requirements, MP-nn processes, RISK-nn / PRISK-nn dispositions, KC-nn mitigations, or CF-nn carry-forwards.
  • The engineering domain(s) involved.
  • The inherited classification — Trivial / Balanced / Exploratory, taken from the Concept Selection Table or Manufacturing Concept Table entries the package realizes, governing its estimation uncertainty treatment.
  • The dependencies on other work packages, by WP-nn reference.
  • The completion criteria — the verifiable condition under which the package is done. "Done" is always demonstrable: a passed verification, an approved document, an accepted deliverable — never a percentage.

3.4.Completeness Checks#

Before the WBS is carried forward, verify:

  • Every in-scope requirement of the PRS, SRS, and NPI Specification baselines is realized by at least one work package and verified by at least one verification activity (Chapter 10) — or excluded by the recorded release scope decision of Chapter 2.
  • Every work package traces back to baseline elements or carry-forwards. A work package with no ancestry indicates scope creep or a missing baseline update, both of which must be resolved — the latter through Chapter 11.
  • Every carry-forward in the register is covered by a resolution work package.
  • Every mitigation with planning impact from the DFMEA, threat analysis, PFMEA, and Key Component Risk Table — validation builds, qualification activities, added verification — appears in a work package, as the originating guidelines promised it would be "budgeted".

4.Development Lifecycle, Integration Stages, and Decision Gates#

4.1.Objective#

Before effort can be scheduled, the shape of the development must be chosen: how the work iterates, where the design freezes, which physical sample stages exist, and where the customer decides. These choices are recorded explicitly with their rationale, because they are among the most consequential planning decisions — they determine how expensive a late change is and how early a problem becomes visible.

4.2.Lifecycle Selection#

The lifecycle model is selected per engineering domain, reflecting the iteration economics documented in the SRA Device Architecture chapter: software changes are cheap and favour short iterations; hardware respins are expensive and favour gated, sample-based progression; mechanical tooling is the most expensive of all and freezes earliest. A typical multi-domain product therefore combines an iterative software track with a gated hardware/mechanical track, synchronized at the integration stages defined below. The chosen model — and the synchronization mechanism between tracks — is documented with rationale, not assumed.

Where the product domain mandates a lifecycle or documentation regime (e.g., medical or automotive development process standards identified in the PRS Regulatory NFRs), the mandated model is adopted and the standard cited — the same authority treatment as everywhere else in the process.

4.3.Sample and Integration Stages#

The plan defines the physical sample stages and what each is for. Typical stages, applied as appropriate to the product:

  • Engineering samples — first integrated hardware, built in low quantity, possibly hand-assembled; used to verify the Device Architecture, retire integration risk, and resolve remaining carry-forwards. Imperfection is expected and budgeted: the estimate assumes at least one hardware respin unless the risk register justifies otherwise, and the assumption is stated either way.
  • Design validation samples — design-representative units used to execute the verification programme against the SRS and PRS: environmental, reliability, EMC, and pre-certification testing.
  • Production validation samples / pilot builds — units built by the EMS partner on the intended processes with the intended test stages, validating the NPI Specification: process capability, production test coverage, takt, and yield. This stage is planned jointly with the EMS partner and consumes the pilot-build work packages of the NPI Specification.

For each stage the plan records: purpose, quantity and build responsibility (internal vs. EMS), the verification activities it carries (Chapter 10), the entry criteria (which work packages must be complete), and the exit criteria (which questions the stage must have answered).

4.4.Milestones#

Milestones are recorded in the Milestone Table, with for each: a stable identifier of the form MS-nn, the name, the verifiable completion condition, the work packages it depends on, and the date once scheduling (Chapter 6) is complete. Milestones mark demonstrable states — "design validation testing passed", not "design validation phase ends".

4.5.Decision Gates#

Decision gates are the subset of milestones at which a deliberate decision is taken before the project proceeds. The governing rule for their placement: a gate is placed immediately before each irreversible or expensive-to-reverse commitment. Typical gate positions include: release of PCB layout to fabrication, release of tooling (the single most schedule- and cost-committing decision in most projects), lifetime or buffer component buys, certification submission, EMS volume-production contract signature, and the start of volume ramp.

Each gate is recorded in the Decision Gate Table with: a stable identifier of the form DG-nn, the commitment it protects, the entry criteria (which evidence must exist — typically verification results, validation findings, or risk-register status), the decision authority (our organisation, the customer, or joint — a customer-authority matter agreed here, not assumed), the options at the gate (proceed, iterate, hold, descope), and the consequence of each option for schedule and cost. Gate criteria are defined now, before any schedule pressure exists, for the same reason the FMEA guidelines demand rating scales before rating begins: criteria defined under pressure drift toward whatever avoids delay.

5.Effort and Cost Estimation#

5.1.Principles#

The estimate is constructed under the following principles:

  • Bottom-up at work package level. Every effort figure is estimated per work package, by the people who will perform or lead the work, and reviewed by a second competent estimator. Top-down figures (analogy with previous projects, parametric models) are used as a cross-check on the bottom-up total, never as a substitute for it; a material divergence between the two is investigated, not averaged.
  • Classification drives uncertainty. The Trivial / Balanced / Exploratory classification inherited by each work package (Chapter 3) is the primary driver of its estimation treatment. Trivial packages are estimated by analogy with routine work and carry narrow ranges. Balanced packages carry the design effort their trade-off studies revealed. Exploratory packages and carry-forward resolution packages carry wide ranges and, where the range is unacceptably wide, an explicit re-estimation point after the early feasibility work — the estimate then states which figure is committed and which is provisional pending that point.
  • Every number has a basis. Each estimate records its basis of estimate: the artifact, analogy, quotation, or calculation it derives from (e.g., "Concept Selection Table FM-07 trade-off study, option B integration effort"; "EMS RFQ response, fixture NRE"; "analogy with project X module Y, corrected for added interface count"). An estimate whose basis is "engineering judgement" is permitted but visible — and a plan dominated by such lines is a finding, not a plan.
  • No hidden padding. Individual work package estimates are honest most-likely figures with stated ranges. Uncertainty is carried by the explicit, separately owned contingency of Section 5.4 — never smeared invisibly into individual packages, where it both inflates the total and hides where the real uncertainty lives.

5.2.Method#

For each work package, a three-point estimate is produced: optimistic, most likely, and pessimistic effort, with the conditions under which each end of the range applies. The spread is consistent with the package classification — a Trivial package with a 3× spread or an Exploratory package with a ±10% spread both indicate a misclassification or a misunderstood scope, and are challenged in review.

Effort is estimated in person-effort per competency (Chapter 7), so the estimate directly feeds the resource plan. Duration is not estimated here; it follows from effort, resource availability, and dependencies during schedule construction (Chapter 6). Conflating effort and duration at estimation time is a classic source of schedule fiction.

5.3.Cost Consolidation#

The full project cost picture is consolidated from:

  • Development labour — the WBS effort estimates priced at the applicable rates.
  • Material cost — the preliminary BoM estimate from the SRA, at the PRS target volume, plus prototype and sample material across the stages of Section 4.3 (sample-stage material is frequently forgotten and is itemized explicitly).
  • Industrialisation NRE and recurring adders — from the IRA Industrialisation Cost Estimate: tooling, fixtures, test equipment, validation runs, pilot builds, and the recurring assembly/test/yield/packaging/logistics adders.
  • Certification and compliance cost — accredited lab testing, certification body fees, and regulated-domain audits, per the NFRs and the test plan.
  • Licences, royalties, and tooling — software licences, IP royalties, and development tooling identified by the concepts.
  • Procurement and travel — long-lead buys committed during development, supplier and EMS engineering visits.

The consolidation preserves the discipline of the earlier pricing chapters: assumptions and remaining exclusions (e.g., margins, duties, post-ramp sustaining engineering) are stated explicitly in every estimate, so the figure is never mistaken for a price. Each cost line traces to its source artifact, completing the chain the SRA and IRA estimates began.

5.4.Contingency and Accuracy Class#

Contingency is derived, not declared: it is computed from the consolidated risk register (Chapter 9) — the cost and schedule exposure of the identified risks weighted by likelihood — plus the aggregate estimation uncertainty implied by the three-point ranges. A flat percentage applied to the total is not acceptable as the sole basis, because it severs the link between risk and reserve and makes the contingency indefensible in customer review.

Contingency is owned (typically by project management, with defined release rules) and visible as its own line. The estimate as a whole states its accuracy class — the expected range of the final figure around the estimate — consistent with the maturity of its inputs, and identifies the re-estimation points (typically the early decision gates) at which the class tightens.

5.5.Evaluation Against the Business Case#

The consolidated picture — development cost, NRE investment profile, landed unit cost at volume, and time to market — is evaluated against the PRS Business Case Background, completing the series of evaluations the SRA performed for material cost and the IRA for the production cost stack. An incompatibility is a principal trigger of the feedback loop of Chapter 11: a change proposal presents the options — reduced release scope, relaxed requirements, alternative concepts, revised volumes, revised positioning, or phased investment — rather than leaving the conflict to surface during contract negotiation or, worse, mid-development.

6.Schedule Construction#

6.1.Dependency Network#

The schedule is constructed on the work package dependencies of the WBS, the sample-stage entry criteria, and the gate placements — not on a desired end date worked backwards. Backward scheduling from a customer market window is performed only as a comparison: where the forward-constructed schedule and the market window conflict, that conflict is a finding for Chapter 11, with options (scope, resources, parallelization, risk acceptance) presented for decision — never resolved by silently compressing estimates.

6.2.Critical Path and Long-Lead Items#

The critical path is identified and examined explicitly. The preceding phases flagged long-lead items precisely so they would appear here: custom test equipment and fixtures (Production Test Strategy), tooling (Manufacturing Concept Table and Industrialisation Cost Estimate), long-lead and allocation-risk components (Key Component Risk Table), high-cost or scarce verification facilities such as EMC chambers and accredited labs (Initial Product Test Plan), and certification body lead times. Each flagged item is verified to be on the schedule with its quoted — not assumed — lead time, ordered at the earliest gate that responsibly permits commitment, and tracked as a schedule risk where its lead time approaches or exceeds the slack available.

6.3.EMS and Supplier Alignment#

The schedule is aligned with the EMS partner's committed dates for DFM completion, fixture and test development, process validation runs, and pilot builds, and with supplier lead times for key components — including the qualification lead time of any second source the Key Component Risk Table mandates. These external dependencies are recorded as such in the schedule, with the owning party named, because schedule risk on an external dependency is mitigated differently (contracts, buffers, alternatives) than internal risk (resources, scope).

6.4.Schedule Buffers#

Like cost contingency, schedule buffer is explicit and placed deliberately — typically protecting the gates and the integration stages — rather than hidden inside individual task durations. The buffer sizing references the risk register and the estimation ranges, and buffer consumption is a defined gate-review topic during execution.

7.Resource and Competency Planning#

7.1.Content#

From the per-competency effort estimates, a staffing profile over time is constructed per engineering domain (hardware, embedded software, FPGA where applicable, mechanical) and per cross-cutting role (system engineering, test engineering, project management, quality). The plan records:

  • The required competencies, including any scarce or specialist skills the concepts demand (identified from the Concept Selection Table — an exploratory concept frequently implies a specialist).
  • The capacity reality check — required staffing against actually available capacity in the relevant period. A plan that requires more of a competency than exists is a finding, resolved by re-sequencing, hiring, contracting, or scope discussion — never by leaving the over-allocation in the plan.
  • Key-person dependencies — single individuals whose unavailability would stall a critical-path work package, recorded as risks in the register with mitigation (knowledge sharing, pairing, documentation).
  • External resources — contracted engineering, the EMS partner's industrialisation engineers, and specialist consultants, with their availability windows treated as external dependencies per Section 6.3.

7.2.Output#

The result is a resource-loaded schedule in which every work package has an owner and a feasible staffing, and a competency gap list with closure actions where gaps exist. Resource assumptions (availability percentages, start dates of hires or contractors) are recorded with the estimate assumptions of Chapter 5.

8.Supplier and EMS Alignment#

This activity converts the external relationships established in the preceding phases into the commitments the plan depends on:

  • EMS agreements — the engagement formalized during the IRA is developed into the agreements covering industrialisation execution: NRE scope and pricing, engineering support during development, pilot-build terms, and the framework for the volume production agreement (the latter typically concluded at the corresponding decision gate, not now). The agreed sourcing model from the Supply Chain Analysis — turnkey, consigned, or hybrid — is reflected in the contractual structure, with its consequences for liability and buffer ownership carried over unchanged.
  • Key component commitments — for each KC-nn component whose mitigation requires a supply agreement, availability commitment, or buffer arrangement, the procurement action is scheduled with its owner; for each mitigation requiring qualification work, the corresponding work package and its decision gate are referenced.
  • Procurement plan — the long-lead purchases committed during development (components for sample stages, tooling, test equipment), each tied to the gate that releases it.

Customer-imposed suppliers or partners are treated exactly as the IRA treats a mandated EMS partner: as documented constraints, with any shortfall against what the plan needs recorded as a risk.

9.Project Risk Register#

9.1.Consolidation#

The project risk register is the single instrument that carries risk into execution. It is seeded, not started blank: the DFMEA and threat analysis items (RISK-nn), the PFMEA items (PRISK-nn), the Key Component Risk Table items (KC-nn), and the Carry-Forward Register items (CF-nn) whose dispositions or resolutions have residual project impact are consolidated into it, each with a cross-reference to its origin. To these are added the risks that only this phase can see: estimation uncertainty on exploratory packages, resource and key-person risks, external dependency risks (EMS, suppliers, certification bodies), and market-window risk.

9.2.Format#

Each register entry carries: a stable identifier of the form RR-nn (Risk Register), the origin reference where seeded, the risk statement (condition → consequence), the assessment (likelihood and impact on cost, schedule, and product, using scales documented before assessment begins — the same discipline as the FMEAs), the owner, the mitigation or response with its work package or gate reference where the response is planned work, and the residual exposure after mitigation.

9.3.Integration#

The register is wired into the rest of the plan rather than standing beside it: mitigations that are work appear in the WBS; risks that gate commitments appear in gate entry criteria; the aggregate exposure drives the contingency and buffers of Chapters 5 and 6; and the register is a standing agenda item of every decision gate. A risk whose mitigation appears nowhere in the plan is an unfunded intention, and is treated as a finding.

10.Verification, Validation, and Certification Planning#

10.1.Objective#

The Initial Product Test Plan (SRA) established that every requirement has a verification path and what it needs; the Production Test Strategy (IRA) defined per-unit production verification. This chapter turns the development-verification side into scheduled, resourced reality, and coordinates it with the production side.

10.2.Content#

The plan defines:

  • The verification programme per sample stage (Section 4.3): which SRS and PRS requirements are verified at which stage, by which method, with which equipment and facilities. The verification-method indications recorded per requirement in the SRS and the NPI Specification are the input; full coverage of the in-scope requirement set is the completeness condition.
  • The test infrastructure plan — the equipment, fixtures, and facilities the Initial Product Test Plan flagged, each with its availability date set against the date the schedule needs it. Custom test development is a WBS work package; external facilities are booked dependencies.
  • The certification path — per certification region from the Business Case Background: the applicable schemes, pre-compliance testing placement (early enough that a failure is a design iteration, not a launch delay), formal submission milestones, certification body lead times, and the documentation obligations of regulated domains.
  • The validation activities with the customer — acceptance of the product against the PRS, planned as explicit milestones with agreed acceptance criteria (which the PRS already carries per requirement).

DFMEA, threat-analysis, and PFMEA mitigations that took the form of added verification are checked off against this plan — closing the promise, made when each disposition was recorded, that the verification would be budgeted and planned.

11.Requirements Feedback and Change Control#

11.1.Purpose#

The PRS, SRS, and NPI Specification are baselined documents; planning findings that affect them are processed through structured change control, never informally. This chapter routes PDP findings to the correct baseline, completing the feedback architecture of the preceding phases.

11.2.Triggers#

A change proposal is raised when PDP work shows that:

  • The full cost picture or NRE investment profile is incompatible with the Business Case cost positioning or the customer's stated budget ceiling (Section 5.5).
  • The forward-constructed schedule is incompatible with a market-window constraint, and the resolution options require a scope, requirement, or positioning change (Section 6.1).
  • A resource or competency constraint makes a requirement or concept unexecutable as specified within realistic staffing.
  • A supplier or EMS quotation contradicts an assumption a baseline was built on (a cost figure, a lead time, a capacity commitment).
  • The release scope confirmation (Section 2.4) re-prioritizes requirements in a way that changes the PRS prioritization or its dependency consistency.

11.3.Routing and Format#

Findings are routed by the authority of the affected baseline, using the established instruments unchanged: product-level impact → a PRS Change Proposal (PCP-nn), decided by the customer; system-level impact → an SRS Change Request (SCR-nn); industrialisation impact → an NPI Specification change through the change control established at NPI baselining. A single planning finding may produce several coordinated records — a schedule conflict resolved by descoping may touch all three — and the records cross-reference each other.

11.4.Re-Baselining#

Accepted changes produce revised baseline versions with updated identifiers and change-log entries, exactly as in the preceding phases, and the plan artifacts (WBS, estimate, schedule, risk register) are updated to the new baselines. At phase end, the Product Development Plan traces to a single identified version of each baseline, and every deviation from the phase-start baselines is covered by a decided change record.

12.The Product Development Plan#

12.1.Purpose#

The Product Development Plan is the formal output of the PDP phase and of the pre-development process as a whole. It consolidates the work breakdown, the lifecycle and gates, the estimate, the schedule, the resource plan, the supplier alignment, the risk register, and the verification plan into a single document that defines how the product will be developed — the baseline against which development execution is contracted, governed, and measured.

12.2.Document Structure#

The Product Development Plan is structured as follows:

# Chapter Content
1 Introduction Purpose, scope, referenced PRS / SRS / NPI Specification versions, IRA applicability decision where relevant.
2 Document Conventions ID schemes (CF-nn, WP-nn, MS-nn, DG-nn, RR-nn); the authority test as extended in this phase; basis-of-estimate and accuracy-class conventions.
3 Planning Baseline The Planning Baseline Record; the Carry-Forward Register; the confirmed release scope with the customer's scope decision recorded.
4 Work Breakdown Structure The Work Package Table with traceability and completion criteria.
5 Lifecycle, Milestones, and Gates Lifecycle selection with rationale; sample and integration stages; Milestone Table; Decision Gate Table with entry criteria and decision authority.
6 Estimate Effort estimates with basis-of-estimate records; consolidated cost picture; contingency derivation; accuracy class; assumptions and exclusions; Business Case comparison.
7 Schedule Dependency network; critical path with long-lead items; external dependency alignment; buffer placement.
8 Resources Staffing profile per competency; capacity check; key-person dependencies; external resources.
9 Supplier and EMS Alignment Agreements to be concluded; procurement plan; KC-nn commitment status.
10 Risk Register The consolidated RR-nn register with origins, owners, mitigations, and exposure-to-contingency linkage.
11 Verification and Certification Plan Verification programme per sample stage; test infrastructure plan; certification path; customer validation milestones.
12 Reference Materials Glossary; referenced standards; source documents (baseline versions, quotations, closing-review records); decided PCP / SCR / NPI-change list.
A…Z Appendices Detailed estimate worksheets; quotation summaries; extended schedule views; Open Items Summary of any genuine stakeholder-authority [TBD]/[TBC] items.

12.3.Review and Baselining#

The Product Development Plan undergoes internal review (including independent review of the estimate by estimators not involved in producing it), EMS partner review for the chapters that bind the partner, and customer review. Once approved, it becomes a baselined document; subsequent changes follow structured change control. Together with the baselined PRS, SRS, and NPI Specification, it forms the basis for the development contract and the production-related agreements.

13.Phase Completion and Exit Criteria#

The PDP phase is offered as a separately purchasable project, and it ends at the most consequential decision point of the pre-development process: the customer's go/no-go into development. The phase is complete when the following exit criteria are satisfied; the closing review walks this checklist explicitly and records the result.

13.1.Coverage#

  • Every in-scope requirement of the baselined PRS, SRS, and NPI Specification is realized by at least one work package and covered by a planned verification activity — or excluded by the recorded release scope decision.
  • Every work package traces back to baseline elements or carry-forwards; the trace is verified in both directions.
  • Every carry-forward from every preceding closing review appears in the Carry-Forward Register with an owner and a scheduled resolution point.
  • Every long-lead item flagged by the preceding phases appears in the schedule with a quoted lead time and a releasing gate.

13.2.Decisions#

  • The lifecycle, sample stages, milestones, and decision gates are defined, and each gate has agreed entry criteria and an agreed decision authority.
  • The release scope is confirmed and recorded as a customer decision, and the scope cut passes the dependency consistency check.
  • Every estimate line has a recorded basis of estimate, and the bottom-up total has been cross-checked top-down with any material divergence investigated and resolved.

13.3.Risk#

  • The risk register is seeded from all preceding risk artifacts with cross-references, every entry has an owner and a response, and every mitigation that is work appears in the WBS or in a gate criterion.
  • Contingency and schedule buffers are explicit, derived from the register and the estimation ranges, and owned.
  • The resource plan contains no unresolved over-allocation, and key-person dependencies are registered with mitigations.

13.4.Baseline Integrity#

  • All raised PCPs, SCRs, and NPI change records are decided, and the affected baselines have been re-baselined accordingly; the Product Development Plan traces to those single versions.
  • The Product Development Plan is reviewed (internal, EMS where applicable, customer) and baselined.
  • The WBS, estimate, schedule, resource plan, risk register, and verification plan are mutually consistent with the baselined plan document.

13.5.Commercial#

  • The full picture — development cost, NRE investment profile, landed unit cost at volume, and time to market — has been evaluated against the Business Case, and any conflict has been resolved or escalated through a change proposal.
  • The contractual structure for development execution (and, where applicable, the framework for production agreements) is agreed to the level the customer needs for the go/no-go decision.
  • The estimate's accuracy class and its re-estimation points are stated and understood by the customer.

Open items deliberately carried into development execution are permitted — but only as explicit, listed, owned carry-forwards in the closing review record, never as silent gaps. With this closing review, the pre-development process delivers its final and central promise: a known, agreed state — requirements, design direction, industrialisation approach, plan, price, and risk — on which the customer can base the informed decision to develop the product.