I have worked in aerospace research institutes, state-owned enterprises, and private companies, gaining experience in scientific research, small businesses, and mid-sized enterprises. From a naive and fearless student to an electronic designer, and eventually to a technical manager, this has been the path many electronics engineers have taken. I’ve written down my reflections on the misunderstandings I faced along the way, hoping they might be useful for others who are just starting out. My goal is to help teachers and peers avoid common pitfalls from the very beginning.
When designing, it's better to use standard components rather than custom ones. Customization often leads to issues with quality control, especially when dealing with small batches. Suppliers may not invest enough in material quality, which can result in defects that are hard to trace later.
Avoid picking random components from retail markets. The problem is that these parts often have poor batch consistency, and the suppliers may not have strict control over their sourcing. Experienced engineers know that even a small mistake during production can cause big headaches later. It’s easy to overlook this when you’re under pressure, but it’s crucial to maintain quality throughout the process.
Don’t make hasty decisions. Once a design is approved and production starts, any change can create a cascade of problems. For example, if a new version of a board is released, what happens to the old stock? Can the new one replace the old one? How do you handle leftover materials or semi-finished products on the line? These issues can quickly become overwhelming. I made such mistakes early in my career and had to leave the job. Now I look back with regret and hope my boss will forgive me. Some people ask, “Would you like to fix the issue?†My answer is usually “maybe.†Some problems aren’t worth solving because the risks outweigh the benefits. So, don’t decide lightly, and once you do, stick to your decision—unless there’s a critical reason to change, like safety or performance concerns.
Reducing the number of device types can improve efficiency. For instance, if a board requires 5 devices, each needing 2 hours of testing, using 10 devices would reduce the time per device to just 1 hour. That doesn’t mean the testing is less thorough—it’s about optimizing resources. Using fewer device types simplifies procurement, supplier management, and inventory control. It also reduces the chances of errors and makes the overall system more reliable.
Inventory management should also be simplified. Instead of keeping multiple resistor values like 5.1Ω and 10Ω, consider combining them. This reduces the total number of items you need to stock, lowers costs, and minimizes the risk of shortages. It’s also easier to maintain and manage fewer types of components. Think about field maintenance too—having fewer part types means you can respond faster when something goes wrong, reducing downtime and increasing convenience.
Using fewer devices increases product reliability. Reliability is calculated as the product of each component’s reliability. Adding more components introduces more failure points. High-integration devices can simplify the design and improve stability. While some may argue that discrete components offer more flexibility, the trend is toward integration, especially in modern electronics. Young engineers should focus on mastering integrated solutions, which are becoming increasingly common and easier to work with.
Try to use components that are already in your company’s library. This ensures that there are experienced people who understand the device, making troubleshooting and support easier. When a device is widely used, its flaws are more likely to be discovered and addressed. It’s like seeing a beautiful woman on the street—just because you see her in a bad light doesn’t mean she’s not capable. Embrace the challenges, because deep understanding helps avoid future problems. Plus, using existing components saves time and money by avoiding unnecessary purchases.
The level of electronic engineering isn’t determined by the tools or chips you use. Many engineers think that working with advanced platforms like ARM or DSP means they’re more skilled, but that’s a misunderstanding. Advanced tools don’t automatically make you better. Just like driving a BMW doesn’t mean you're a better driver than someone in a simpler car. True expertise comes from solid fundamentals—like engineering calculations, reliability analysis, electromagnetic compatibility, and a deep understanding of basic electronics. These are the real building blocks of good design.
These are some of the lessons I've learned through experience. I hope they can help others avoid similar mistakes. Remember: strong basics, consistent practice, and clear thinking are the three pillars of success in this field.
Problems with failing factory relays, connectors/terminals and fuse contacts are also common when excessive load is placed on them.
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