5 ways to reduce cost

Updated: Jul 6



Here are 5 quick ways to reduce cost (and increase profits) in your device:

  1. Reduce labor:

  2. Simplify assembly processes

  3. Introduce fixtures to speed up assembly

  4. Plan for assembly automation

  5. Design for snap catches instead of screws or adhesive

  6. Automated adhesive dispensing (when adhesive can’t be avoided)

  7. Common parts/screws to simplify decision making

  8. Poka-yoke.

  9. Design with assembly in mind (!) surprising, but this one gets skipped frequently

  10. Reduce materials cost

  11. Select lower-cost materials (tradeoff is quality)

  12. Design smaller parts (to reduce raw material cost)

  13. Consolidate parts

  14. Replace custom components with off-the-shelf components

  15. Reduce the weight of material

  16. Increase tooling/capital expense

  17. Multi-cavity tools drastically reduce part cost

  18. Batch processing reduces unit cost

  19. Add manufacturing processes in-house that are typically outsourced

  20. Add automation/robots. All the robots.

  21. Remove non-critical functionality

  22. Remove charging capability – design for user-replaceable battery

  23. Eliminate display; put display functionality on smartphone

  24. Remove buttons; put button functionality on smartphone

  25. Eliminate removable power cord, design integrated power cord.

  26. Is soft-touch finish required? Can painted soft-touch replace insert-mold?

  27. Can a color LCD be replaced by an e-ink display?

  28. Do you really need IP-67 waterproof rating?

  29. Reduce packaging costs

  30. Shrink packaging size

  31. Redesign for off-the-shelf packaging

  32. Simplify packaging design, change user experience

  33. Use lower-cost processes that match order volumes


Can you think of any that I missed?


I’m an expert in design of injection molded parts and complex mechanical devices. Do you need help? I’d love to help design/engineer your next project.


Make it an excellent week!




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