The algorithm for unlocking margins
Radical cost reduction isn't magic — it's a repeatable engineering process. I ran it hundreds of times at Tesla across six vehicle platforms. The same four steps work every time.
Question the Requirements
In the rush to meet launch deadlines, engineering compromises become permanent fixtures in your BOM, eating into margins year after year. I start by ruthlessly questioning legacy specs. Most parts are over-engineered to solve problems that no longer exist.
Delete & Consolidate
The best part is no part. Before redesigning anything, I look at what can be deleted entirely, then audit the system architecture to combine components into fewer, highly manufacturable geometries. Every deleted fastener is a failure point and supply chain headache removed.
Optimize for Automation
A cheap part that requires complex manual dexterity to install is actually incredibly expensive. I design geometries specifically for fast cycle times and modern robotics, drawing on experience developing 5-second cycle-time compliant robotic installs.
De-Risk the Design
Cost-down never means quality-down. Through rigorous FEA, CFD, and fatigue analysis, I identify exactly where to trim material while maintaining strict factors of safety. The result is lighter, cheaper, and mathematically validated to outlast your warranty period.
The Deal
Standard (Capped)
$50K engagement fee
Creditable against gain-share
10% of first-year savings
Capped at $1M total fee
Best for companies who want cost certainty
If your annual production costs are over $10B, please reach out directly to discuss custom at-scale pricing.
Standard pricing terms reviewed annually.
Frequently asked questions
How do we determine the baseline cost? Are tooling costs factored in?
We establish a 'Baseline BOM Cost' using your actual supplier invoices from the previous 12 months. Both parties sign off before redesign begins. Gain-share is calculated on Net Savings — when redesigns require new tooling, that CapEx is amortized over the part's planned production life.
What if you audit our line but can't find savings?
You pay nothing. Any engagement fee is refunded and you walk away with a free expert validation of your manufacturing line.
What if we decide not to manufacture the redesigned part?
A pre-negotiated kill-fee covers the engineering execution.
How are first-year savings calculated when production volumes change year-over-year?
First-year savings = (baseline unit cost − new unit cost) × units shipped in the 12 months after SOP. Volume swings flow through to fee in both directions, subject to caps.
What CAD and simulation tools do you use?
CATIA V5, SolidWorks, Onshape, Fusion 360. For validation: ANSYS and SimScale.
Do you provide a full design package?
Yes — updated 3D CAD, detailed 2D drawings, and strict GD&T. Ready for your suppliers.
What if a redesigned part fails testing?
I revise at no additional cost. No performance fees until the part passes all validation and enters production.
Can we scope an engagement to a single subsystem?
Yes — scope flexes from a single subsystem to a full product, and the gain-share model works cleanly at any scale. Phased engagements are common.
Will you travel for tool trials?
Yes. I attend T0/T1 trials on-site, globally. Based in Singapore, currently most active across Mainland China, Taiwan and Southeast Asia.
Do you work alone?
For focused audits, I'm the lead engineer. For larger projects, I bring in a trusted network of senior colleagues.
Do you work with startups or do prototyping?
The gain-share model is for mass manufacturing. For NPI and prototyping, contact me to discuss flat-rate or equity structures.
Do you offer fractional engineering leadership?
Yes — weekly design reviews, manufacturing strategy, and DFM coaching.
Do you partner with other agencies?
Yes — we work as a specialist DFM and cost-reduction layer for design firms and larger agencies.
How long does a typical engagement take?
Audits run 2–4 weeks. Redesign and validation typically take 8–16 weeks depending on subsystem complexity and tooling lead time. Most clients see redesigned parts on the production line within 4–6 months of kickoff.
How do you work with our internal engineering team?
Alongside, not instead of. Your engineers know the product, the field history, and the constraints I don't. I bring the external eye and the willingness to question requirements baked in for years. Senior reinforcement, not replacement.
How do you handle confidential CAD data?
We access your PLM/PDM via secure VPN or client-provisioned VM. Data stays on your servers. Standard NDAs signed before any technical discussions.
Do you sign non-competes?
Yes — reasonable, targeted non-compete clauses for your specific product category.