Learning from Software Development

John Miller, Dwayne Stroman

When we think about Agile and SAFe® (Scaled Agile Framework) in the hardware world, one of the first questions that comes up is:

“How can we split our work into meaningful, testable increments the way software teams do?”

Hardware, firmware, and integrated system teams operating as part of a Lean Product Development effort in an enterprise or portfolio, often feel constrained by long lead times, physical prototypes, and compliance requirements. But the truth is, the principles use in software development are the same — we just need to translate them into a hardware context.

Software teams have decades of experience decomposing features into small, testable User Stories. Hardware, firmware, and integrated system teams, however, often feel constrained by long lead times, physical prototypes, and compliance requirements. But the truth is, the principles are the same—we just need to translate them into a hardware context.

As Donald Reinertsen, author of The Principles of Product Development Flow, said:

“The goal is to move knowledge forward fast enough to improve decision-making, not to get the perfect design on the first try.”

By splitting User Stories effectively, hardware teams can accelerate learning, reduce risk, and align more seamlessly with software and systems teams in a SAFe® Agile Release Train (ART).

Why Story Splitting Matters in Hardware

Story splitting is not just an Agile activity; it’s a mindset shift. When hardware teams adopt smaller increments of work:

• Feedback loops accelerate—teams learn what works earlier.
• Integration risks decrease—problems are discovered sooner.
• Compliance confidence grows—incremental verification starts earlier.
• Collaboration improves—hardware and software roadmaps align naturally.

For example, automotive companies moving to electrified drivetrains split work into incremental prototypes for torque distribution, battery safety tests, and embedded firmware integration. Each “slice” delivers learning without waiting for the full vehicle build.

Mapping Hardware Work into Story Splits

In software, we often split stories by UI elements, data flows, or API endpoints. In hardware, the same principles apply—but the story categories are different. Below are hardware-centric story splitting types and how they map to real-world engineering:

1. Business (The “Touch It and Adjust It” Side)

• These are the customer-facing or user experience elements: knobs, switches, displays, and mechanical performance.
• Example: Splitting a washing machine control panel into “basic power button,” “cycle selector,” and “LED feedback.”
• Quote: “If you can’t touch it, you can’t trust it.” – Common adage in mechanical R&D

2. Architecture

• Hardware architecture stories focus on system-level structure—mechanical, electrical, and control.
• Example: Splitting an electric vehicle drivetrain into motor configuration, inverter interface, and cooling loop design.
• Key difference from software: Dependencies on physical geometry, materials, and thermal properties.

3. Compliance

• Compliance starts with software-style validation but expands into physical and regulatory domains.
• Example stories:
  • “Design PCB to meet FCC Part 15 emissions.”
  • “Prepare UL shock hazard test plan for enclosure.”
• Agile value: Compliance becomes incremental instead of a late-phase gate.

4. Infrastructure

• Hardware teams also need enabling infrastructure:
  • Fixtures for assembly
  • Test rigs for repetitive validation
  • Calibration equipment
• Example: “Build a vibration test fixture for 10kg assemblies.”
• Quote: “If your tools are slow, your learning is slow.” – Adapted from Lean Product Development

Next-Level Story Splits for Hardware R&D

Once the feature-level splits above are clear, teams can break work into smaller, testable slices using these R&D-oriented patterns:

1. Interfaces – Verify or simulate connection points early

1. • Example: “Validate USB-C power interface for thermal rise under 2A load.”

2. Delivery Pipeline (Industrial DevOps) – Enable frequent builds and tests

1. • Example: “Automate environmental chamber logs into central database.”

3. Digital Twins – Create early system models for simulation and verification

1. • Example: “Simulate torque distribution in digital twin before first prototype.”

4. Test Beds – Physical environments to test hypotheses

1. • Example: Wind tunnel tests at Boeing or vibration/shock (“shake & bake”) for satellites.

5. Models – Graphical, computer, or physical

1. • Example: CAD assembly of a gearbox; MATLAB thermal model; printed scale mock-up.

6. Specification Models – Calculations or tolerance studies

1. • Example: “Calculate thermal margin for battery pack at 2C discharge.”

7. Prototypes – From paper/cardboard to metal fab

1. • Example: “3D-print simplified housing to test assembly ergonomics.”

8. Non-Functional Requirements – (NFRs)

1. • Example: “Ensure enclosure meets IP65 water ingress rating.”

9. SBD (Set-Based Design) Trade Studies

1. • Example: “Compare 3 materials for thermal expansion and cost; eliminate lowest performer.”

10. Engineering Analysis – Thermal, vibration, fatigue, or FEA

1. • Example: “Perform thermal cycling FEA on PCB assembly.”

11. Compliance (Incremental) – UL, FCC, environmental

1. • Example: “Conduct preliminary EMI scan in lab to guide layout before certification.”

Bringing It All Together

To be truly Agile in hardware, teams must:

• Split stories into small, testable increments—not wait for the “full build.”
• Map work into categories (Business, Architecture, Compliance, Infrastructure) to ensure no critical aspect is missed.
• Adopt R&D patterns (Interfaces, Prototypes, Models, Test Beds) to accelerate learning.

As Mary Poppendieck often reminds us:

“The goal is to learn fast enough to make good decisions before the cost of change skyrockets.”

By embracing story splitting for hardware, teams create faster learning cycles, reduce surprises late in the lifecycle, and align hardware with Agile software teams for true systems agility.

Call-to-Action for Readers

• Review your current hardware backlog: Are your stories too large or too late to test?
• Identify one upcoming feature and split it using the patterns above.
• Ask: How soon can we touch it, test it, and learn from it?

This is how lean product development of hardware meets Agile—one story slice at a time.

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