Orange Line / Work

Example results.

Unless otherwise approved, client identities are held confidential. Engagement outcomes are described in the range we delivered, verified in supplier quotes, shipped parts, or engineered redesigns.

−48%

Peak BOM reduction

−50%

Peak logistics reduction

4+

Industries served so far

3–52wks

Engagement range

Case / 01

150 components, redesigned for cost.

Connected Home GoodMechanical & ElectricalOLV CoreConfidential

Context: a consumer hardware product at the edge of cost viability.

The product was finished, tooled, and had been shipping for years, but its profit margins were pinched. The client needed a path back to healthy margins without reopening the industrial design or forcing heavy requalification through the manufacturer.

Approach: a detailed mechanical and electrical rebuild against the same ID, functionality, and UX.

We respected what was working and tackled what wasn't. Rather than re-specifying every part, we focused on the components where meaningful cost was hiding. Packaging was reworked end-to-end with chargeable-weight as a core cost-down target. The product that comes out the other side looks the same, feels the same, and ships with a fraction of the cost.

Move / 01 · Component consolidation

Mechanical and electrical part count reduced where cost was hiding. Assemblies simplified. Materials and processes pressure-tested against the function they actually needed to perform.

Move / 02 · Packaging redesign

Box geometry and internal structure rebuilt against the new product envelope, cutting chargeable weight in half.

−48%
Full BOM cost reduction
& −50% chargeable weight
Mechanical & electrical redesign
Case / 02

Full BOM cost-out on a deployed city infrastructure product.

City InfrastructureFull BOM · 8 WeeksOLV CoreShipped

Context: a plateau the internal team couldn't break through.

Production was happening. The internal team had been working for months to bring down the cost. Negotiations with suppliers had reached a point where each additional dollar was harder to find than the last, and the prevailing view was that the floor had been hit. It hadn't.

Approach: should-cost modeling with the tools to back it up.

The unlock was the rigorous should-cost methodology the team had developed at SpaceX: material, process, labor, tooling, and margin decomposed with enough fidelity to hold up across the table from suppliers who'd heard every argument before. Iteration on negotiation tactics and packaging density alongside that model is where the savings came from.

Move / 01 · Should-cost negotiation

First-principles cost model built at component and assembly level, used as the negotiation basis across active suppliers. Iterated across multiple rounds.

Move / 02 · Packaging density

Box and pallet geometry reworked to improve units-per-shipment math without changing product protection performance.

−30%
Landed cost reduction
Delivered in 08 weeks
Verified in shipped parts · Plan of record
Case / 03

Logistics redesign for a scaling aircraft fleet.

Drone · Aircraft ProgramFreight & Packaging · 6 MonthsOLV CoreShipped

Context: a logistics program nobody thought had room.

Cost pressure was real, but the prevailing view internally was that the logistics program had no room to cut. Packaging and freight were uncontrolled and arbitrary, with significant cost sitting in a lack of specification and shipping clarity. Suppliers were over-designing and over-packaging. Chargeable weight on inbound shipments was dramatically high compared to actual payload.

Approach: simulations, Paretos, and physical testing to prove the cost out.

We ran packaging simulations to bring chargeable weight down. Pareto analyses surfaced the biggest cost-drivers. Physical studies and vibration, shock, and ship-test cycles verified that each proposed cost-down held up before it went live.

Move / 01 · Package geometry

Outer dimensions reduced to match actual product envelope. Internal packing and protective material revised to cut dimensional-weight penalty without compromising protection.

Move / 02 · Physical verification

Vibration, shock, and ship-test cycles run on proposed changes where the risk profile called for it, used to validate cost-downs before field deployment.

−50%
Freight cost reduction
Delivered over 06 months
Verified on active shipments

Think we can find savings in your BOM?

No deck, no hard sell. Just a direct review of your hardware (ideally a costed BOM plus CAD, specs, or samples) and a straight answer on whether we think there's cost to pull out.

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