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)
- $20K engagement fee ($10K on kickoff, $10K on design handover)
- 10% of first-year savings
- Capped at $1M total fee
Best for companies who want cost certainty
If I can't find savings without sacrificing quality, any engagement fee is refunded in full. You pay nothing.
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 — if a redesign requires new tooling, that CapEx is deducted from gross savings first.
What if you audit our line but can't find savings?
You pay nothing. 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.
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.
Will you travel for tool trials?
Yes. I attend T0/T1 trials on-site. I operate in English and Mandarin across Taiwan, China, 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 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.