5 ways to reduce costs by increasing the reusability of your product designs

The benefits of modular design

13/01/2025

The design stage is a crucial part of your product's life cycle, as it has a significant impact on everything else related to the product, including its reusability. So, how can your company improve product design reusability? Here are five effective strategies to help you get started while optimizing your cost structure.

1. Think modular

The foundation of reusability lies in modular design. This means breaking your products down into individual modules that can be reused and applied across various product designs.

For example, consider using the same type of window or door in multiple vehicle models. This not only reduces the complexity of your design process but also lowers production costs by minimizing redundant work and making more efficient use of materials. Modularity allows companies to respond flexibly to changing market demands and accelerates product development.

By implementing standardized modules, you can further reduce research, development, and testing costs, making innovation faster and more economical.

2. Standardize components

The next step in boosting reusability is standardization. Reusable parts with consistent specifications can be applied across different products. For instance, once a specific type of screw or connector is approved, establishing it as the standard across product lines reduces the need for various alternatives. This shortens design cycles and significantly lowers production costs. Moreover ordering larger batches of those standard items often leads to discounts.

Standardization also makes production processes more transparent and easier to manage. For example, if you use the same screws across products, you can also use the same screwdriver. It enables teams to collaborate more efficiently and ensures new developments align with existing processes.

3. Simplify your production processes

Reusable parts and modules help minimize complexity in production. When design choices are standardized, production workflows become more efficient with fewer variations. This lowers production costs by reducing setup times and streamlining manufacturing processes. Additionally, fewer component variations improve consistency and significantly reduce defects. This creates production environments that are less prone to errors and consistently deliver higher-quality products.

4. Optimize inventory costs

A reliable set of reusable components reduces the need for excessive storage space, avoiding overcrowded warehouses. This not only lowers storage costs but also mitigates the risk of obsolescence and waste. Furthermore, with a more streamlined inventory of components, you can plan more efficiently, leading to better demand forecasting and optimized stock levels. Minimizing inventory waste makes companies more agile and less dependent on unpredictable factors in the supply chain, such as disruption or fluctuating raw material prices.

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5. Make maintenance simpler and more efficient

Reusable products also simplify maintenance and repair work. By using standardized components, spare parts can be utilized more broadly, which not only lowers maintenance costs but also speeds up repairs. For customers, this translates to increased reliability and faster service. Moreover, it also lowers the need for different parts in the service vehicles. Reusability also reduces the need for multiple versions of replacement parts, lowering storage complexity and cutting after-sales support costs. This becomes increasingly important as customer service and maintenance take on a bigger role in business strategies.

So, how to implement these 5 strategies?

A strategy focused on reusability requires a holistic approach, with technology playing a pivotal role. A Product Lifecycle Management (PLM) system, such as PTC Windchill, can support the drive toward maximum reusability. Features like centralized data storage, modular design management, version control, and streamlined workflows provide businesses with the tools they need to work consistently and efficiently.

PLM facilitates the implementation of modularity and standardization by keeping all components, designs, and processes centrally documented. This ensures information is always accessible, workflows are optimized, and inefficiencies are minimized. Furthermore, PLM offers the flexibility to adapt to changing market demands, further encouraging the adoption of reusable designs.

Are you ready to explore how reusability can help your company save costs and create sustainable value? Consider investing in a PLM system and discover how technology can make a difference. Allow experts to guide you toward a future with more efficient production processes and greater innovation potential and schedule a discovery workshop to see how PLM can be integrated into your operations.