Designing for Humans: Viewing DFM and Industrialization Through the Lens of the Fitts MABA–MABA List
"Operator’s fault" and "Inadequate Training" are the phrases you typically hear when yield loss and stubborn manufacturing issues are discussed. While these factors may play a role, they rarely tell the whole story. This article views DFM and industrialization through the lens of a classic human factors principle; the Fitts MABA-MABA list, and highlights a critical, yet less-discussed factor: the lack of manufacturing-focused human factors considerations in product design. It explores practical examples like Proprioceptive Fatigue and Visual SNR, and shows how lots of chronic manufacturing issues are results of bad upstream design decisions, echoing the fact that in many cases, inspection exists not because it is inherently valuable, but because the design failed to encode correctness directly into the product or process. If you’ve ever wondered why "retraining" never seems to fix a recurring defect, this take on industrialization and manufacturing might explain why.
Baking in Process Improvements
Jason Sachs uses a backyard cookie-baking session with his niece to illustrate practical process improvements engineers can apply. He documents batch-by-batch tweaks — temperature, dough placement, and a pipelined scooping step — that raised throughput and improved quality, then connects the lesson to pilot projects and small automations like a Python script for JIRA. The piece makes the case for quick experiments and a culture that rewards refinement.
Better Hardware Design Decisions, Faster: A Lean Team’s Guide to MDO
As design complexity grows, siloed decision-making often leads to late-stage surprises, costly rework, and missed opportunities for optimization. Multidisciplinary Design Optimization (MDO) offers a structured approach to solving this by enabling teams to evaluate trade-offs and impacts across the full system before implementation begins. Traditionally used in large, high-budget industries like aerospace, MDO is now within reach for lean teams, thanks to more accessible modeling tools and an urgent need for tighter collaboration. This article outlines how small hardware teams can adopt MDO in a practical way, starting simple, integrating key models early, and building toward a culture of systems thinking. The result is better design decisions, faster development, and more robust, manufacturable products with fewer surprises along the way.
Optimizing Hardware Design: Reducing Iterations with DSM
Often, product teams curate feature roadmaps that fail to account for the interdependencies in product components. For this article, I wrote about how system architecture tools like Design(dependency) Structure matrix (DSM) can be used to evaluate feature roadmaps to avoid the purgatory of change propagation and accompanying endless Iteration loops. These iteration loops are sometimes affordable (manageable) in software development (Agile saves lives), but for hardware teams - especially small product teams and startups - the lost time, and money is the stuff of which product graves are made.
On optimizing manual soldering
When faced with manual soldering of thousands of components, speed and efficiency become pivotal. Here are some takeaways from my own experience attempting to optimize such a process.
My friend, the compiler
Modern compilers were given great powers, but we don't always know where and when they'll use them. This may cause us to either worry needlessly or trust unjustifiably, as demonstrated by a little example in this post.
BusyBox; The Swiss Army Knife of Embedded Linux
In this article we cover the BusyBox, how it's designed to be optimized for embedded targets, and how to configure and build it in different ways, we also covered the license and limitation, which led to the development of ToyBox, I hope you enjoyed the article, please leave a comment for any correction or suggestions.
The Asimov Protocol
While the Internet is choke-full of explanations of basic data communication protocols, very little is said about the higher levels of packing, formatting, and exchanging information in a useful and practical way. This less-charted land is still fraught with strange problems, whose solutions may be found in strange places – in this example, a very short, 60 years old Science Fiction story.
Flood Fill, or: The Joy of Resource Constraints
When transferred from the PC world to a microcontroller, a famous, tried-and-true graphics algorithm is no longer viable. The challenge of creating an alternative under severe resource constraints is an intriguing puzzle, the kind that keeps embedded development fun and interesting.
Handling Translations in an Embedded Project
A brief walkthrough on how to handle human language translations in a low level C application. Some options are listed, each with advantages and disadvantages laid out.
Zebras Hate You For No Reason: Why Amdahl's Law is Misleading in a World of Cats (And Maybe in Ours Too)
Amdahl’s Law is a useful warning, but Jason Sachs argues it can be misleading if you stop at the equation. Using the Kittens Game as a playful model, he shows how Gustafson’s perspective, positive feedback loops, and system-level synergy can turn modest component speedups into big real-world wins. The article closes with concrete embedded-systems examples like ISR timing and developer productivity.
Handling Translations in an Embedded Project
A brief walkthrough on how to handle human language translations in a low level C application. Some options are listed, each with advantages and disadvantages laid out.
Designing for Humans: Viewing DFM and Industrialization Through the Lens of the Fitts MABA–MABA List
"Operator’s fault" and "Inadequate Training" are the phrases you typically hear when yield loss and stubborn manufacturing issues are discussed. While these factors may play a role, they rarely tell the whole story. This article views DFM and industrialization through the lens of a classic human factors principle; the Fitts MABA-MABA list, and highlights a critical, yet less-discussed factor: the lack of manufacturing-focused human factors considerations in product design. It explores practical examples like Proprioceptive Fatigue and Visual SNR, and shows how lots of chronic manufacturing issues are results of bad upstream design decisions, echoing the fact that in many cases, inspection exists not because it is inherently valuable, but because the design failed to encode correctness directly into the product or process. If you’ve ever wondered why "retraining" never seems to fix a recurring defect, this take on industrialization and manufacturing might explain why.
Optimizing Optoisolators, and Other Stories of Making Do With Less
Jason Sachs digs into how to squeeze speed and reliability from low-cost optoisolators, showing practical tweaks that often outperform default datasheet usage. He mixes hands-on circuits — using 4N35 base-emitter resistors, Schottky clamps, input speedup caps, and output buffering — with transistor-switching theory and a cautionary production story to show when to optimize and when to splurge on pricier isolators.
BusyBox; The Swiss Army Knife of Embedded Linux
In this article we cover the BusyBox, how it's designed to be optimized for embedded targets, and how to configure and build it in different ways, we also covered the license and limitation, which led to the development of ToyBox, I hope you enjoyed the article, please leave a comment for any correction or suggestions.
Donald Knuth Is the Root of All Premature Optimization
Knuth's famous line "premature optimization is the root of all evil" has turned into a blunt rule on forums, Jason Sachs argues, and that overuse masks important nuance. He walks through concrete embedded examples, from dsPIC33E floating-point timings to an ROI analysis in the Kittens Game and a continuous optimization toy problem, to show when to measure, when to speculate, and why profilers can mislead.
Assembly language is best - except when it isn’t
A look at why writing in C often produces more efficient code than hand-written assembly language.
Surprising Linux Real Time Scheduler Behavior
An embedded Linux data acquisition project ran into puzzling UART latency whenever heavy UI animations ran. Moving all app threads to SCHED_FIFO helped but did not eliminate delays. After reading about kernel worker thread interactions, Matthew moved the UI back to the normal scheduler and the jitter vanished. The post highlights an unexpected kernel level priority inversion risk and a pragmatic workaround.
Trust, but Verify: Examining the Output of an Embedded Compiler
Jason Sachs argues embedded engineers should read their compiler's assembly even if they rarely write assembly. He walks through Microchip XC16 output for dsPIC33 devices, showing how simple C variants and optimization flags produce very different code. The article demonstrates practical verification techniques and a tiny Python helper, pyxc16, to quickly inspect assembly for timing-sensitive firmware without rewriting everything in assembly.
Baking in Process Improvements
Jason Sachs uses a backyard cookie-baking session with his niece to illustrate practical process improvements engineers can apply. He documents batch-by-batch tweaks — temperature, dough placement, and a pipelined scooping step — that raised throughput and improved quality, then connects the lesson to pilot projects and small automations like a Python script for JIRA. The piece makes the case for quick experiments and a culture that rewards refinement.
Zebras Hate You For No Reason: Why Amdahl's Law is Misleading in a World of Cats (And Maybe in Ours Too)
Amdahl’s Law is a useful warning, but Jason Sachs argues it can be misleading if you stop at the equation. Using the Kittens Game as a playful model, he shows how Gustafson’s perspective, positive feedback loops, and system-level synergy can turn modest component speedups into big real-world wins. The article closes with concrete embedded-systems examples like ISR timing and developer productivity.
Donald Knuth Is the Root of All Premature Optimization
Knuth's famous line "premature optimization is the root of all evil" has turned into a blunt rule on forums, Jason Sachs argues, and that overuse masks important nuance. He walks through concrete embedded examples, from dsPIC33E floating-point timings to an ROI analysis in the Kittens Game and a continuous optimization toy problem, to show when to measure, when to speculate, and why profilers can mislead.
Optimizing Optoisolators, and Other Stories of Making Do With Less
Jason Sachs digs into how to squeeze speed and reliability from low-cost optoisolators, showing practical tweaks that often outperform default datasheet usage. He mixes hands-on circuits — using 4N35 base-emitter resistors, Schottky clamps, input speedup caps, and output buffering — with transistor-switching theory and a cautionary production story to show when to optimize and when to splurge on pricier isolators.
Trust, but Verify: Examining the Output of an Embedded Compiler
Jason Sachs argues embedded engineers should read their compiler's assembly even if they rarely write assembly. He walks through Microchip XC16 output for dsPIC33 devices, showing how simple C variants and optimization flags produce very different code. The article demonstrates practical verification techniques and a tiny Python helper, pyxc16, to quickly inspect assembly for timing-sensitive firmware without rewriting everything in assembly.
[ C Programming Techniques: integer type optimization ]
Microcontroller integer width can make or break ISR performance on AVR. In this post Fabien Le Mentec compares using uint8_t versus unsigned int for a timer counter on an ATmega328P and shows how the smaller type cuts instruction and cycle count in the ISR. He also walks through the trade offs: reduced capacity, volatile access costs, and simple portability fixes such as uint_fast8_t or an architecture-aware typedef.
BusyBox; The Swiss Army Knife of Embedded Linux
In this article we cover the BusyBox, how it's designed to be optimized for embedded targets, and how to configure and build it in different ways, we also covered the license and limitation, which led to the development of ToyBox, I hope you enjoyed the article, please leave a comment for any correction or suggestions.
Assembly language is best - except when it isn’t
A look at why writing in C often produces more efficient code than hand-written assembly language.
Surprising Linux Real Time Scheduler Behavior
An embedded Linux data acquisition project ran into puzzling UART latency whenever heavy UI animations ran. Moving all app threads to SCHED_FIFO helped but did not eliminate delays. After reading about kernel worker thread interactions, Matthew moved the UI back to the normal scheduler and the jitter vanished. The post highlights an unexpected kernel level priority inversion risk and a pragmatic workaround.
Embedded Firmware Refactoring, Optimisation and Migration
Legacy embedded products often hit CPU, memory, or power limits long before customers stop wanting new features. This article lays out three practical paths: squeeze more from the current build with optimisation, make the codebase maintainable through refactoring, or port firmware to new hardware when constraints demand it. Read on for a pragmatic view of when each approach makes sense and how to reduce risk.
Handling Translations in an Embedded Project
A brief walkthrough on how to handle human language translations in a low level C application. Some options are listed, each with advantages and disadvantages laid out.
