Key principles.
Often biggest
7075 to 6061: 40% material cost savings if function allows. PEEK to PPS: 70% cost reduction.
Eliminate features
Each feature costs time. Audit drawing for non-essential features. Combine features when possible.
Per function
Loosen non-critical tolerances. ±0.025 to ±0.05 saves 30-50% on those features.
Reduce assembly
Multiple machined parts into single — reduces fasteners, assembly labor.
CNC to casting
At sufficient volume, casting beats CNC. Tooling investment pays back at scale.
Vs custom
Use standard hardware, threads, sizes. Custom adds time and supply chain complexity.
FAQ
Production-stage products with stable demand. Cost reduction $X per unit × thousand units = significant savings.
Quality regression if material/process change reduces capability. Validate changes before production rollout.
Customer must approve changes affecting form/fit/function. We propose, customer approves.
ECN (Engineering Change Notice) tracks each change. Customer approves before implementation.
Generally 10,000+ units/year justifies redesign investment. Less may not amortize design cost.
Standing VAVE program reviews production parts periodically. Identifies opportunities as supply chain and processes evolve.
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