BOM cost breakdown
Line-by-line cost analysis with drivers identified per product variant and sub-assembly.
Discuss thisDesign & SimulationCost and BOM analysis
Cost and BOM analysis
that shows where the money actually goes.
Cost work is only useful if it identifies where the money sits and what can actually change. We break a product down to its real cost drivers, model the effect of volume and lifecycle, and separate savings that are safe from those that quietly degrade the design.
- Cost driver analysis
- Specification alternatives
- Volume modelling
Why electronics cost reviews failPercentage savings with no
Percentage savings with no
engineering consequence.
A target like “reduce cost by fifteen percent” rarely says where the cost is, what drives it, or which changes would compromise the product. Without that, cost reduction becomes specification stripping that shows up later as returns, field failures or a respin.
We establish the cost structure first, then model specific changes with their consequences stated. You get a ranked list of options with the engineering trade-off attached to each one, not a single unsupported number.
Savings are only real if they survive production. A cheaper part with a longer lead time, a new tooling cost or a shorter lifecycle can cost more overall, so that is always part of the analysis.
- 01Real cost structure
Cost drivers identified per product variant instead of a single blended figure.
- 02Options with consequences
Each saving is presented with its engineering impact, so trade-offs are explicit.
- 03Volume modelled
Costs projected across volumes, so MOQ and tier effects are visible before commitment.
- 04Nothing hidden
One-off tooling, NRE and lifecycle costs included rather than reported separately.
- Per-variant breakdownCosts separated by product variant, so an expensive option is visible rather than averaged away.
- Trade-offs statedEach option presented with the engineering consequence, not just the saving.
- Volume sensitivityPricing modelled across volumes so MOQ and tier effects appear before you commit.
- One-off costs includedTooling, NRE and lifecycle costs sit in the same model as unit price.
What we deliver
Cost and BOM analysis services
Analysis can cover a single product, a range of variants, or an existing design being reworked for cost.
Product teardown analysis
Physical and electronic teardown to understand what a competitor product actually contains.
Discuss thisSpecification alternatives
Engineering options that change cost, each presented with its technical consequence.
Discuss thisVolume & lifecycle modelling
Costs projected across volumes and lifecycle, including MOQ and tier effects.
Discuss thisMake-or-buy assessment
Build versus buy compared on tooling, NRE, volume and ongoing engineering effort.
Discuss thisShould-cost benchmarking
Independent cost expectation for a design, useful before committing to a supplier quote.
Discuss thisWhat is included in scope
Scope is agreed in writing before work starts, so deliverables and responsibilities are clear.
- Product & variant definitionProducts and variants in scope defined, with volumes and lifecycle assumptions stated.
- Cost structure build-upBOM and assembly costs assembled per variant from documented part pricing.
- Driver identificationThe lines that materially drive cost highlighted, with lifecycle and supply risk noted.
- Options modellingEngineering alternatives modelled with their cost impact and technical consequence.
- Volume sensitivityCosts projected across volumes, showing MOQ tiers and one-off tooling where relevant.
- Findings reportRanked findings with options, savings, risk and the re-verification each option would require.
Capabilities
Cost engineering capability
The analysis is only credible if it comes from engineering judgement, because the same saving can be safe in one product and unacceptable in another.
BOM cost modelling
Line-by-line cost build-up with drivers separated by variant and sub-assembly.
Teardown analysis
Physical and electronic teardown used to understand real product content.
Specification review
Alternatives assessed on performance, tolerance, reliability and lifecycle, not price alone.
Volume & MOQ analysis
Tier effects, minimum order quantities and break-point volumes modelled explicitly.
Make-or-buy modelling
Tooling, NRE, engineering effort and volume compared for a genuine decision.
Should-cost benchmarking
Independent cost expectation provided as a reference point against supplier quotes.
Component-level lifecycle and supply questions are covered in component sourcing, and production planning in manufacturing support.
Our process
How a cost analysis runs
Define the product and volumes, build the cost structure, then model options with their consequences.
Scope & assumptions
Products, variants, volumes and lifecycle assumptions agreed before any analysis begins.
Scope and assumptionsCost structure build-up
BOM and assembly costs assembled from documented pricing, with drivers identified.
Cost modelOptions & alternatives
Engineering alternatives modelled with their technical consequences stated.
Options analysisFindings & recommendations
Ranked findings presented with savings, risk and required re-verification.
Cost report
Technologies
Analysis approach and tools
Pricing is documented and dated, because a cost model built on undated catalogue figures is not evidence.
- BOM toolingStructured bill of materials analysis with variant and sub-assembly roll-up
- Pricing evidencePart pricing recorded with source, date, quantity break and currency
- Volume modellingBreak-point, MOQ tier and lifecycle cost projection across volumes
- TeardownPhysical and electronic teardown for benchmarking real product content
- Risk weightingLifecycle and supply risk factored into the cost model, not reported separately
- ReportingFindings ranked by impact, with options and consequences presented together
Every figure in the report carries its source and date, so the model can be re-run when prices or volumes change instead of becoming a snapshot that quietly goes stale.
Industries
Built for your industry’s environment.
Temperature, vibration, electrical transients and certification needs differ by sector, and they are captured during discovery rather than after the first build.
Industrial
Control panels, motor drives, gateways and automation hardware for continuous operation.
IndustrialAutomotive
In-cabin electronics, LED drivers and control units designed around automotive electrical and thermal expectations.
AutomotiveEnergy & power
Monitoring, metering, conversion and control electronics for energy and power systems.
Energy & powerHealthcare
Diagnostic and monitoring devices designed with patient safety and compliance in mind.
HealthcareRailways
Onboard and signalling electronics built for vibration, temperature cycling and long maintenance cycles.
RailwaysBeauty & wellness
Skin, hair and wellness devices with careful low-voltage design and safe user interfaces.
Beauty & wellnessCapability examplesSee the engineering problem.
See the engineering problem.
Imagine the possibilities.
The scenarios below illustrate the kind of work we do — they are not published client case studies or measured results. Ask us about relevant experience for your product.
Illustrative · Product family
A range sharing most of one design
Challenge: One expensive option was hidden inside a blended average across variants.
Approach: Costs separated per variant so the specific part driving cost became visible.
Explore component sourcingIllustrative · Re-specification
A design needing cost reduction
Challenge: A percentage target was set without knowing the cost structure.
Approach: Cost drivers identified first, then options modelled with their engineering consequences.
Explore electronics developmentIllustrative · Supplier quote
A quote that looked competitive
Challenge: A quoted unit price omitted tooling and minimum order effects.
Approach: One-off and volume costs brought into one model for a true comparison.
Explore manufacturing supportFrequently asked questionsGood questions.
Good questions.
Clear starting points.
What buyers usually want to know before scoping this kind of work.
Ask about your requirements →What cost analysis services do you provide?
BOM cost breakdown, product teardown analysis, specification alternatives, volume and lifecycle modelling, make-or-buy assessment, and independent should-cost benchmarking.
How do you calculate cost savings?
Each option is modelled against documented pricing at your volumes, with the technical consequence of the change stated alongside the saving, so the saving can be judged properly.
Do you include tooling and NRE?
Yes. One-off tooling, NRE and lifecycle costs are included in the same model as unit cost, because excluding them makes low-volume options look artificially attractive.
Can you review a competitor product?
Yes. A teardown analysis can establish what a competing product actually contains, which is often more useful than a supplier quote for understanding the achievable cost.
Will cost reduction damage reliability?
Not without us telling you. Where a saving depends on a change in tolerance, protection, thermal margin or lifecycle, that consequence is stated explicitly with the option.
How accurate are the cost figures?
Figures come from documented pricing with source, date, quantity break and currency recorded, so the model can be re-run when prices or volumes change rather than becoming a stale snapshot.
Related services
Design & Simulation
Explore the rest of the programme, or get in touch about this service directly.
Start your projectLet’s find where the cost
Let’s find where the cost
really sits.
Send the bill of materials, tell us your volumes and where the product is in its lifecycle. We will show the drivers first, then the options.
No complete specification needed. A short brief of your product and goals is enough to start.
What happens next?
- Share your product goal, application and current stage.
- Discuss the components, interfaces and constraints that matter.
- Agree a practical next step and the scope for a proposal.