Solutions · Cost Optimization Strategies
Cost Optimization Strategies for Complex Mechanical Programs
We look beyond piece price to optimize your total cost of ownership—across processes, tooling, yield, assembly time, logistics, and lifecycle changes—from prototype through mass production.
📊 DFM / DFMA Cost Optimization 📈 Prototype → MP (EVT / DVT / PVT)
🛠️ Soft → Hard Tooling Strategy 🏭 Global Mfg + Dallas VMI / JIT
Part‑Level DFM / DFMA
Remove unnecessary complexity, tighten or relax tolerances, and align each part with the most efficient manufacturing process.
Assembly & Labor Optimization
Reduce assembly steps, fasteners, and handling to drive down labor time and improve quality.
Lifecycle & Supply Chain Cost
Design around volume ramp, risk, and logistics to keep your total landed cost under control over the full product lifecycle.
Why Cost Optimization Starts with Engineering
Most long‑term cost is locked in by early design decisions. We work with your engineers to make those decisions intentionally—instead of relying on last‑minute purchasing pressure.
Total Cost, Not Just Unit Price
We look at tooling, scrap, rework, assembly time, logistics, field failures, and change costs in addition to per‑piece pricing.
- Compare total landed cost scenarios, not just quotes
- Identify high‑impact levers for cost reduction
- Align with finance, supply chain, and engineering goals
Cross‑Process, Cross‑Supplier Perspective
Because we manage multiple processes and suppliers, we can see where a different manufacturing route or vendor mix creates savings.
- Machining vs. casting vs. molding trade‑offs
- Global vs. regional manufacturing options
- Consolidation of parts, processes, and suppliers
Structured, Repeatable DFM / DFMA
Our DFM process uses checklists, templates, and benchmarks to quickly identify cost risks and improvement opportunities.
- DFM reports mapped to your drawings & BOM
- Prioritized list of suggested design changes
- Quantified cost and risk impact where possible
Core Cost Optimization Strategies
We apply a set of proven strategies across your mechanical design and supply chain to uncover and capture savings without sacrificing quality.
1
Design Simplification
- Reduce part count where possible through consolidation
- Eliminate unnecessary features and “nice‑to‑have” geometry
- Standardize hardware, fasteners, and interfaces
2
Tolerance & Finish Optimization
- Relax tolerances that are tighter than function requires
- Align cosmetic expectations with realistic finishing options
- Focus tight controls only where they add real value
3
Process & Material Selection
- Choose the right process for each volume and geometry
- Evaluate material alternatives with similar performance
- Use common materials across the BOM to simplify sourcing
4
Tooling & Volume Strategy
- Bridge tooling for early builds, hard tooling for ramp
- Plan tool family strategies across similar parts
- Phase investments based on realistic demand curves
5
Assembly & Labor Efficiency
- Design for fewer assembly steps and less handling
- Introduce poka‑yoke features and clear orientation cues
- Optimize work instructions and fixturing for takt time
6
Supply Chain & Logistics
- Consolidate shipments and packaging where feasible
- Use VMI / JIT to balance inventory vs. stock‑out risk
- Optimize INCO terms and shipping modes by region
Download Liquid Cooling Design Checklist
Key Cost Levers We Analyze
| Cost Lever | What We Look At | Typical Optimization Actions |
|---|---|---|
| Geometry & Features | Complex pockets, undercuts, thin walls, deep ribs, sharp corners. | Reshape features, adjust wall thickness, or split parts to reduce machining, tooling, or scrap. |
| Tolerances & GD&T | Position, flatness, perpendicularity, and tight bilateral limits. | Relax non‑critical controls, refine datum schemes, and align with realistic process capability. |
| Material & Finish | Selected alloys/plastics, coating stack‑ups, cosmetic specs. | Switch to cost‑effective equivalents, simplify finishes, or zone cosmetic requirements. |
| Assembly & Testing | Fasteners, adhesive steps, test points, and rework rates. | Introduce snap‑fits or common fasteners, group tests, and build in error‑proofing. |
| Tooling & Capacity | Tool life, cavitation, cycle time, and spare/tooling strategy. | Increase cavitation, balance cycle time vs. tool cost, and plan spares ahead of demand growth. |
Balancing Cost, Quality & Risk
Cost optimization is not about cutting corners—it’s about spending money in the right places and proving that changes are safe before they go into production.
Data‑Driven Decisions
Use Cpk, scrap, and cycle‑time data to guide changes Quantify risk and savings for each proposal Document assumptions and validation plans
Controlled Change Management
Engineering change orders with clear scope Pilot builds and limited releases for risky changes Customer approvals where required
Long‑Term Partnership View
Cost roadmaps over the product’s life Joint workshops to review performance and opportunities Alignment with your future platform and derivative plans
When to Apply Cost Optimization in Your Program
Cost optimization is most powerful when it’s threaded throughout the development process—not saved for the final RFQ.
Concept & Architecture
- Align on major process choices and part count
- Avoid locking in overly complex concepts
- Set realistic cost and performance targets
Design & EVT
- Apply DFM / DFMA to initial drawings and models
- Prototype with cost in mind, not just speed
- Start building your cost database early
DVT / PVT
- Validate actual process capability and yield
- Refine tolerances, finishes, and inspection plans
- Lock tooling strategies and capacity plans
Mass Production & Sustaining
- Monitor scrap, rework, and field issues
- Execute continuous improvement & cost‑down projects
- Adjust volumes, tooling, and logistics as demand shifts
Ready to Build a Cost Optimization Plan for Your Program?
Cost roadmaps over the product’s life
Joint workshops to review performance and opportunities
Alignment with your future platform and derivative plans
1
Ready to Build a Cost Optimization Plan for Your Program?
Provide part list, annual volumes, and current targets. Get a high‑level cost‑driver summary and suggestions within 5–7 days.
2
Schedule a Cost Strategy Call
Walk through your challenges with our team and align on priorities, timing, and success criteria for cost‑down work.
3
Combine with DFM / DFMA Workshop
Run a focused session on one sub‑assembly or product to see how design and process changes can create measurable savings.
