Issue link: https://iconnect007.uberflip.com/i/1541840
38 DESIGN007 MAGAZINE I DECEMBER 2025 The most persistent chokepoints in the elec- tronics design lifecycle stem from fragmented cross-functional communication, late-stage design changes, and insufficient early-stage planning, particularly around electrical constraints, FPGA pin assignments, and manufacturability. Many organizations run on the "throw it over the wall" approach to the design process, which refers to a dysfunctional workflow where one team completes their part of a project and then hands it off to another team with little to no collaboration, context, or follow-through. This approach creates a cascade of inefficiencies and miscommunication. Without proper context, critical details are often lost in handoffs, leading to confusion and costly rework. The absence of a feedback loop means receiving teams struggle to clarify intent or ask questions, which slows progress and fosters frustration. This disconnect can breed a finger-pointing culture, where accountability gives way to blame when issues arise. Ultimately, misalignment between teams results in delays, bottlenecks, and a break- down in workflow conti- nuity, making the entire process more reactive than resilient. These issues not only stall progress but also increase the likelihood of rework, introduce risk, and compress already tight layout windows. This lack of early collaboration leads to mismatched expectations, overlooked constraints, and missed opportunities for optimization. Designers may not be informed of critical updates, such as compo- nent substitutions, specification deviations, or fab limitations, until it's too late to adapt without signif- icant disruption. These bottlenecks are magnified in a highly complex design. Tighter signal margins, aggressive power delivery targets, and shrinking time-to-market windows leave little room for error. In many projects, PCB layout begins before the conceptual design has been fully fleshed out—a practice that's surprisingly common. This often stems from a desire to maintain the illusion of prog- ress: the design engineer may mark the initial design phase as "complete" to keep the timeline on track and satisfy milestone optics. However, this superficial checkpoint masks deeper issues. By initiating layout prematurely, the project inad- vertently sets itself up for cascading delays. Incom- plete schematics, unresolved constraints, and vague mechanical boundaries force the PCB designer into a reactive posture—tasked not only with the board layout but also with reconciling upstream ambi- guity. The result? The burden of catching up falls squarely on the layout team. We expect design- ers to absorb the shortfall, troubleshoot incon- sistencies, and somehow deliver on time despite inheriting a moving target. This practice not only compresses layout timelines but also increases the risk of rework, missed constraints, and fabrication errors. In high-complexity designs, where signal margins are razor-thin and manufac- turability is non-nego- tiable, this approach is particularly damaging. It undermines the integ- rity of the design flow and erodes confidence in schedule predictabil- ity. The cumulative effect of fragmented planning and reactive workflows is all too familiar: late nights, design rework, and mounting frustration. PCB designers often race against a clock that was mismanaged from the start, trying to compensate for upstream delays, incomplete inputs, and shifting requirements. The paradox couldn't be more evident: With better coordination, much of this pressure could be alleviated, enabling designers to meet deadlines while preserving work-life balance. Yet, the pattern persists. Project timelines continue to be driven by optics rather than readiness, and layout teams bear the brunt of the fallout. An effective solution to this dysfunction is decep- tively simple: Co-locate a small, cross-functional B E YO N D D ES I G N " " The paradox couldn't be more evident: With better coordination, much of this pressure could be alleviated, enabling designers to meet deadlines while preserving work-life balance.