Design simplification
Review of part count, geometry, interfaces and assembly structure to remove unnecessary complexity.
Vehicle Engineering Services
Cost-Oriented Engineering Support
Engineering support for reducing vehicle, system and component costs while protecting function, reliability, manufacturability and project requirements.
Engineering Objective
Cost reduction must be based on engineering evidence
Cost pressure should not lead to uncontrolled material changes, unsuitable components or production problems. TLG SYSTEMS reviews the complete technical solution to identify where cost can be removed without creating unacceptable functional, quality or manufacturing risks.
The cheapest component does not always create the cheapest vehicle
Purchase price is only one part of the total cost. Tooling, assembly time, weight, rework, supplier dependency, service access, warranty exposure and production complexity must also be considered.
Service Scope
Cost improvement across product, process and supply
The analysis can focus on one component, a complete system or selected areas of a vehicle project.
Material optimisation
Evaluation of material grade, thickness, standard profiles and manufacturing requirements against the actual design loads.
Manufacturing review
Identification of bending, machining, welding, tooling and tolerance choices that create avoidable production cost.
Component standardisation
Replacement of unnecessary custom parts with suitable standard components where function and integration permit.
Supplier alternative studies
Technical evaluation of alternative suppliers, equivalent components and second-source opportunities.
Assembly and service improvement
Reduction of assembly operations, difficult access, adjustment time and unnecessary maintenance complexity.
Cost Drivers
Typical areas examined during the study
The analysis considers the cost created throughout procurement, production, vehicle integration and service.
Excessive part count and duplicated functions
Over-specified materials, thicknesses or tolerances
High machining time and unnecessary precision operations
Complex welded assemblies and difficult fixture requirements
Low-volume custom parts that can be standardised
High-weight solutions affecting payload and operating efficiency
Long assembly, alignment or adjustment operations
Rework caused by unclear interfaces or unsuitable tolerances
Single-source dependency and weak supplier alternatives
Poor service access and avoidable maintenance time
Project Workflow
From cost baseline to controlled engineering actions
Baseline
Existing design, component cost, production method and project requirements are reviewed.
Identify
High-cost parts, processes, interfaces and technical risks are identified.
Develop
Alternative concepts, materials, components and production solutions are prepared.
Compare
Cost potential, technical effect, implementation effort and risk are compared.
Implement
Approved actions are converted into design, sourcing or manufacturing changes.
Decision Principles
Cost, performance and risk must be evaluated together
Protect required function
Cost actions are checked against functional requirements, interfaces and expected operating conditions.
Measure total impact
Purchase price, tooling, production effort, weight, service and supply risk are considered together.
Control implementation risk
Each proposal is evaluated for validation needs, documentation changes and possible effects on the vehicle project.
Any design or material change requiring calculation, testing,
validation or approval must be verified before implementation.
Final technical and commercial decisions remain under the customer’s
authority.
Start a Cost Study
SEND PROJECT INFORMATION
Need to reduce product cost without losing engineering control?
Send us the available drawings, bill of materials, production information, annual quantities and known cost targets. We will evaluate the potential work scope and prioritise the main cost drivers.