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Editor's note: Engineering stories are not necessarily about milliamps, volts and HDLs. In this one, Frank saves a young EE's career with generous doses of fajitas and tequila.

I returned to my office one Tuesday afternoon to find a call from Jack McGill, my Florida rep, on my answering machine. "Meet me at Pancho's for lunch," Jack's disembodied voice said. "We have a Three Margarita Engagement."

This was serious. I immediately went online and booked a flight to Florida. A fax to Jack with flight details and Wednesday's itinerary was complete.

It was a hot, humid August in New York, but that did not prepare me for Florida. My jacket was off ten feet past the doors of the air-conditioned terminal. My tie loosened before I got in the car. My shirt was still turning into a sponge.

Jack briefed me as the A.C. cooled the car. "His name is Scott Brady. Graduated from a local college with an EE degree last year. Started working at Harral last September. Their new development group is utilizing the RF knowledge of the Military Satellite Division and computer capability of the Modem people. The product is a Cell Site for cellular phone systems. Scott was hired to be the power supply specialist. Scott majored in computer science so he really wants to be in software. He's been on the job for nine months now and is ready to quit. I thought you might help him."

I replied, "You mean to tell me that a huge company like Harral would spend tens of millions of dollars to develop a product that could be their future, and leave the power supply design to an inexperienced youth?"

"Yup," Jack said.

Scott looked tired when we met him in the Harral lobby. I introduced myself and we drove to Pancho's in silence. Once inside, waiters set a basket of chips, salsa and three Cuervo Gold Margaritas on the table. As we looked over the menus, a tray of Nachos and Guacamole dip arrived, I thought, "How well Jack does this. They know him and automatically set up the agenda."

Scott took a few sips and a few chips and looked better. Jack broke the ice. "This is Grindle. He can help you. Tell him the story." The story Scott related is common enough. It goes like this.

"I didn't know anything about power supplies. The people gave me their voltage, current and ripple requirements. They kept changing them. The size was dictated by the mechanical people based upon what was left after all the other hardware was designed. It was very small. I was given a sample boilerplate for the input, environmental and testing. I made up a specification based on this data. Purchasing sent it to thirty companies and only three responded. Two said they wanted more room. We went to one with no exceptions."

"Did you pay them any Non Recurring Engineering?" I asked.

"No, we told them that we expected to build ten thousand of these supplies and that they could amortize the NRE over the production volume."

"And they agreed? Did you give them a purchase order for ten thousand pieces?"

"No they just assumed that they would get that order. We gave them an order for ten prototypes."

"Why am I here?" I asked.

Jack said, "The PO was given in April. It is now August and no prototypes. No company. The power supply company is bankrupt. They took this job expecting to use it as a means to obtain investment capital. They couldn't get the prototype working and couldn't get the money. So here is Scott without a supplier. The mechanical design is about finished, the boards are ready for staging with actual power and it appears that the power supply is not going to be here for a good six months. Scott will take the blame."

As Scott downed his second Margarita the fajitas arrived. He started to cry. There goes his chance to be a programmer.

"Scott," I said, "Don't fall for that. If you think that once you succeed in designing a power system you will be transferred to programming, think twice. I started down the same path as you thirty seven years ago. I loved RF. I was a radio amateur building transmitters. They promised me RF work. 'But first we must power the Traveling Wave Tubes' they said. I never got out of Power."

Scott still was shaking. I then said, "However, I just happen to have the exact power supply you need. My company developed one for Motocom for the same type of Cell Site. We can supply a unit modified to your specifications in about two weeks."

Scott said, "And if you do, and it works, will I have to spend the rest of my life working in power supplies?" "Yes" I said.

"I don't think I want your help," Scott replied, attacking the third Margarita. He smiled and staggered to the men's room. Jack said, "You blew it." I answered "I just saved a young man's life." We both smiled. Scott returned walking tall. He had a smile on his face. He knew what he had to do.

The above story shows three things happening today in our industry. One is the concept that inexperienced people can specify power requirements. Two is that Purchasing is too anxious to place orders with the lowest, and in this case, the only bidder without evaluating the supplier's capability, and three is that companies exist that will bid and accept jobs beyond their engineering and financial capability

It also is a warning that success in specifying and obtaining a power supply might be injurious to one's career.

Frank Greenhalgh

About the Author

Frank Greenhalgh has been working in power supplies and systems for 38 years. He has many impressive accomplishments and patents. Over the years he has made significant contributions to Trio Laboratories where he held the position of Chief Design Engineer and was then promoted to Vice President.