Case Studies
Our Results Speak for Themselves
Below are a few examples of how we’ve helped past clients achieve their cost reduction goals.
Case Study #1: Electronics
Client Situation:
- Large Tier 1 Automotive Supplier
- Product: Electric Vehicle Power Electronics
- Circumstances:
- The Client was requested by OEM to reduce Bill of Materials by 17%
- Cost reduction strategy was a requirement to win OEM business
Cost Reduction Approach:
- Complete forensic level design, material and manufacturing analysis
- Substitution of lower cost components where applicable
- Recommendations for design changes to achieve the client’s cost target
Results:
- Identified potential material cost reduction of 27% and $7.5 million in annual savings
- The identified cost reduction strategy satisfied the OEM, which allowed the client to participate in the component bidding process.
Case Study #2: Mechanical
Client Situation:
- Large Tier 1 Automotive Supplier
- Product: Differential
- Circumstances:
- Current margin was too low
- Needed to identify cost drivers and identify potential cost savings
Cost Reduction Approach:
- Full cost analysis on the assembly to identify cost drivers
- Engineering observations to improve manufacturing processes
Results:
- Identified machining processes that were too long
- Provided recommendation for shorter process, saving approximately 30 minutes per differential unit
- Provided cost estimate for additional capital and tooling to implement the new process
Case Study #3: Medical
Client Situation:
- Medical Company
- Product: Disposable Syringe
- Circumstances:
- The client initiated a cost reduction program to reduce costs by 30/40%.
- Syringe is the first high volume product to be analyzed
Cost Reduction Approach:
- Evaluate the entire injection molding process and assembly/packaging
Results:
- Identified potential material cost reduction of 50%
- Client did not anticipate the identified cost reduction potential considering the 1 million unit volume.
For more information about our services or to request a meeting with a member of our organization, contact us today.