01 · The challenge
A successful product had become a margin problem. Component prices had risen, the board carried two generations of workarounds, and the enclosure took eleven screws to assemble.
02 · What we did
- 01
Bought, tore down and benchmarked the client’s product against three competitors, with a should-cost model for each.
- 02
Consolidated two boards into one, moved to a single wireless SoC and removed a separate display controller.
- 03
Redesigned the enclosure to snap-fit with two screws, keeping the premium feel the brand is known for.
- 04
Ran a full regression test campaign so nothing customers relied on changed.
03 · The outcome
The redesigned product cut BOM cost by 38% and assembly time by 41%, restoring the margin needed to keep the product line in retail.
“We expected a list of ideas. We got a finished product.”