On products shipping hundreds of thousands of units a year, saving ¥0.1 per harness is serious money — but not at the cost of reliability. Four proven paths:
1. Consolidate materials
Consolidate to 2-3 wire gauges and connector families across a product line; volume concentration cuts unit price 10-20% and reduces changeover errors.
2. Design for simpler processes
DFM review: crimp instead of solder, mold instead of glue, replace hand-taping with pre-formed sleeves. One door-lock retrofit cut labor 40% per piece.
3. Connector value engineering
Qualified domestic connectors now match certification at 30% lower cost; keep premium brands on critical power loops, substitute elsewhere.
4. Automated testing
One-dock automated continuity fixtures take test time from 2 minutes to 15 seconds per piece and eliminate human misses.
Final words
We offer DFM cost reviews and framework pricing for high-volume programs: +86 184 0755 1752 / eric@muyenda.com.