Mastering Design to Cost for Competitive Advantage
You're under pressure. Margins are shrinking. Stakeholders demand innovation, but finance pushes back. You know great design matters, but unless it's cost-competitive from the start, it won't get approved. You're stuck between creative excellence and financial discipline, and no one gives you a clear method to bridge the two. That ends today. Mastering Design to Cost for Competitive Advantage is the proven system used by top engineering leads, product managers, and design strategists to deliver high-performance products that are both market-leading and cost-optimised from the earliest concept phase. Imagine walking into your next innovation review with a fully cost-aware design framework, backed by structured methodology, and a board-ready business case that proves competitive advantage through intentional cost architecture. No more last-minute cost overruns. No more rejected prototypes. Just confident, data-backed decisions that win approvals and outpace competitors. One senior mechanical engineer at a global automotive OEM used this exact approach to redesign a drivetrain component. By applying the Design to Cost frameworks in this course, they reduced component cost by 23%, improved energy efficiency by 11%, and secured executive buy-in for full production - all within 11 weeks. This isn't theoretical. This is how elite product teams create defensible market positions through technical excellence tightly coupled with cost intelligence. You’ll go from uncertain sketches and spreadsheet battles to a strategic, repeatable process that delivers funded, recognised, and future-proof innovation. Here’s how this course is structured to help you get there.Course Format & Delivery Details Self-paced, on-demand, and built for professionals who lead innovation under real-world constraints. This course is designed for engineers, product developers, supply chain strategists, and innovation managers who need deep mastery without sacrificing execution time. You gain immediate online access the moment you enrol, with full flexibility to learn at your own speed, on any device. Immediate Access, Lifetime Learning
Once you enrol, you’ll receive a confirmation email followed by access details when your course materials are ready. There are no fixed start dates, no weekly modules to wait for, and no forced timelines. You progress at your pace, revisiting concepts whenever needed. Complete the core content in as little as 14 hours, with most practitioners applying key techniques to live projects within the first 5 days. Real results start fast - such as identifying 15%-30% cost savings in existing designs during your very first module. Lifetime Access & Future Updates
You don’t just get the course. You get lifetime access to all materials, including every future update at zero additional cost. As cost models, industry benchmarks, and design tools evolve, your training evolves with them. Your investment compounds over time. Mobile-Friendly & Global Access
Access your course anytime, anywhere. Whether you're on-site, in transit, or working remotely across time zones, the platform is optimised for mobile, tablet, and desktop - with 24/7 availability and seamless sync across devices. No installations. No compatibility issues. Direct Instructor Insight & Support
You’re not learning in isolation. This course includes structured guidance from veteran design-to-cost consultants with 20+ years of experience in automotive, medical devices, industrial equipment, and consumer electronics. You’ll receive access to expert-authored templates, decision guides, and support answers vetted by specialists. Trust & Recognition: Certificate of Completion by The Art of Service
Upon finishing the course, you’ll earn a Certificate of Completion issued by The Art of Service - a globally recognised credential that validates your expertise in cost-driven design. This certificate is shared widely on LinkedIn, cited in performance reviews, and used by professionals to justify promotions, project leadership, and innovation mandates. The Art of Service has trained over 120,000 professionals worldwide in high-impact operational disciplines. This credential carries weight because it reflects applied knowledge, not just theory. Transparent, Risk-Free Enrollment
Pricing is straightforward, with no hidden fees, subscriptions, or surprise charges. You pay once, gain full access, and keep it forever. The course accepts all major payment methods, including Visa, Mastercard, and PayPal - securely processed with bank-level encryption. Your confidence is protected by our absolute commitment to your success: complete the course and apply the methods within 90 days, and if you don’t see measurable value in how you approach product design and cost, you’re covered by our full refund guarantee. “Will This Work for Me?” - We’ve Got Your Back
You might be thinking: I’m not a cost engineer. I don’t lead pricing teams. I’m not in procurement. This won’t apply to me. Wrong. This works even if you're a design engineer with no formal cost training, a product manager without direct budget authority, or a technical lead navigating internal resistance. The frameworks are role-agnostic, process-driven, and built for cross-functional leverage. As a systems architect in aerospace, I had zero influence over supplier contracts. But after applying Module 5’s Target Cost Allocation model, I redesigned our avionics cooling subsystem to meet strict cost guardrails - and my VP called it 'the most cost-intelligent proposal we’ve seen in years.' - Miguel R., Senior Systems Engineer, Canada I used the Cost Map and Design Margin Tool from Module 8 on a consumer packaging project. We cut material spend by 18% without sacrificing sustainability claims. The marketing team loved it, finance approved instantly. - Lena K., R&D Manager, Germany This course gives you the language, tools, and confidence to influence cost outcomes - regardless of your formal authority. Your ability to connect design decisions to financial impact is what sets you apart. We make that connection undeniable.
Module 1: Foundations of Design to Cost Thinking - Understanding the difference between cost reduction and cost-driven design
- Why traditional cost-cutting fails in product development
- The strategic importance of cost as a design parameter
- Linking customer value to manufacturing and lifecycle cost
- Common misconceptions about Design to Cost in engineering organisations
- Mapping stakeholder pain points across engineering, finance, and procurement
- The role of innovation in disciplined cost management
- Case study: Redesigning a medical device housing using early-stage cost modelling
- Introducing the Design to Cost maturity model
- Self-assessment: Where does your organisation stand?
Module 2: Defining Competitive Price and Target Cost - Market-based pricing vs cost-plus pricing strategies
- How to benchmark competitor product pricing using public data
- Deriving allowable cost from market price and margin requirements
- Factoring in distribution, service, and warranty costs
- Calculating target cost by product segment and region
- Adjusting for inflation, currency, and commodity volatility
- Setting stretch targets without killing innovation
- Using voice-of-customer data to align cost with perceived value
- Validating target cost assumptions using focus groups and conjoint analysis
- Creating a dynamic target cost dashboard for tracking
Module 3: The Design to Cost Framework and Process Flow - Overview of the 7-phase Design to Cost lifecycle
- Integration with stage-gate and agile product development
- Key decision points for cost validation in each phase
- Defining cross-functional ownership of cost outcomes
- Setting up Design to Cost gates in your innovation funnel
- Aligning technical reviews with financial checkpoints
- Creating a Design to Cost charter for your project
- Introducing the Design to Cost playbook
- Using cost-phase mapping to prevent late-stage changes
- Case study: Managing cost gates in a hybrid EV powertrain project
Module 4: Cost Modelling and Estimation Techniques - Bottom-up vs top-down cost models: when to use each
- Creating parametric cost models based on geometry and materials
- Using process-based costing for manufacturing operations
- Estimating material costs using current commodity indices
- Labour cost estimation by region and skill level
- Overhead allocation methods for R&D and indirect costs
- Building a bill-of-cost (BOC) alongside the bill-of-materials (BOM)
- Data sources for accurate cost inputs (public, internal, third-party)
- Validating estimates against historical builds and supplier quotes
- Managing uncertainty: confidence intervals and sensitivity analysis in cost models
Module 5: Target Cost Allocation and Decomposition - Breaking down system-level target cost to subsystems and components
- Allocation methods: functional, mass-based, value-based, and risk-weighted
- Using functional analysis to prioritise cost investment
- Creating a target cost waterfall chart
- Handling cost overruns at the subsystem level
- Balancing cost targets with reliability and performance targets
- Using design margins to buffer against cost uncertainty
- Managing trade-offs between cost, weight, and durability
- Interactive exercise: Allocate target cost for an electric scooter drivetrain
- Best practices for updating allocations during design evolution
Module 6: Design for Assembly and Manufacturability (DFAM) - How part count reduction drives cost and quality improvements
- Applying design simplification principles to mechanical systems
- Standardising components and fasteners across product lines
- Minimising handling, orientation, and insertion complexity
- Using assembly time estimation models (e.g. DFA index)
- Designing for high-volume automated production
- Leveraging modular design to reduce process variation
- Selecting manufacturing processes with built-in cost advantages
- Comparing casting, stamping, injection moulding, and additive trade-offs
- Case study: Reducing assembly steps in a diagnostic device by 60%
Module 7: Material and Process Optimisation - Selecting materials based on cost per unit function (e.g. strength per dollar)
- Alternatives to high-cost alloys and specialty plastics
- Using material substitution matrices for technical feasibility checks
- Life cycle cost analysis of material choices
- Sourcing strategies: domestic vs offshore, single vs dual sourcing
- Negotiating with suppliers using technical cost models
- Designing tolerances that match process capability
- Reducing scrap rate through robust design
- Lean principles in material usage and nesting efficiency
- Environmental and regulatory impact on material cost
Module 8: Cost Mapping and Design Margin Management - Visualising cost distribution across a product using heat maps
- Identifying cost outliers and hidden cost drivers
- Creating a cost responsibility matrix (CRM)
- Setting internal design cost margins to protect against overruns
- Differentiating between controllable and structural costs
- Tracking cost performance index (CPI) for design teams
- Using earned value concepts in product development
- Managing cost risk in prototype iterations
- Building cost transparency into daily engineering decisions
- Interactive exercise: Cost map a smart home thermostat assembly
Module 9: Value Engineering and Function Analysis - Applying Value Methodology (VM) in early design phases
- Conducting function analysis using FAST diagrams
- Distinguishing between necessary and secondary functions
- Identifying over-design and under-design in current products
- Using function-cost matrix to prioritise improvements
- Running cross-functional value analysis workshops
- Linking function performance to customer satisfaction metrics
- Generating creative alternatives using structured brainstorming
- Validating function-cost balance through customer testing
- Case study: Improving battery life while reducing bill-of-materials cost
Module 10: Tolerance and Quality Cost Optimisation - Understanding the cost of variation in manufacturing
- Linking tolerance specifications to process capability (Cp/Cpk)
- Using tolerance stack-up analysis to avoid over-constraining
- Applying Taguchi loss function to quantify quality cost
- Reducing inspection burden through robust design
- Designing controls for common cause vs special cause variation
- Linking reliability goals to warranty cost predictions
- Using failure mode and effects analysis (FMEA) for cost avoidance
- Setting acceptable risk levels based on cost impact
- Standardising validation tests to reduce development cost
Module 11: Supplier Integration and Early Involvement - The role of suppliers as design partners in cost innovation
- Selecting suppliers based on technical capability and cost insight
- Setting up early supplier involvement (ESI) protocols
- Sharing target cost data without revealing IP
- Using competitive bid analysis to validate cost assumptions
- Managing supplier quote discrepancies with technical negotiation
- Building joint cost models with key vendors
- Managing global supplier cost creep due to logistics
- Negotiation tactics based on cost model transparency
- Case study: Co-developing a sensor module with a Tier 1 supplier
Module 12: Digital Tools and Cost Simulation - Overview of Design to Cost software platforms
- Using CAD-integrated cost estimation plugins
- Automated feature recognition for manufacturability scoring
- Simulation tools for thermal, stress, and flow analysis to prevent over-design
- Linking PLM systems to cost databases
- Creating digital twins for cost and performance validation
- Using AI-assisted cost suggestion engines
- Dashboarding cost KPIs for engineering leadership
- Version control for cost models and design iterations
- Exporting cost data for ERP and financial systems
Module 13: Advanced Cost Trade-off Analysis - Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Understanding the difference between cost reduction and cost-driven design
- Why traditional cost-cutting fails in product development
- The strategic importance of cost as a design parameter
- Linking customer value to manufacturing and lifecycle cost
- Common misconceptions about Design to Cost in engineering organisations
- Mapping stakeholder pain points across engineering, finance, and procurement
- The role of innovation in disciplined cost management
- Case study: Redesigning a medical device housing using early-stage cost modelling
- Introducing the Design to Cost maturity model
- Self-assessment: Where does your organisation stand?
Module 2: Defining Competitive Price and Target Cost - Market-based pricing vs cost-plus pricing strategies
- How to benchmark competitor product pricing using public data
- Deriving allowable cost from market price and margin requirements
- Factoring in distribution, service, and warranty costs
- Calculating target cost by product segment and region
- Adjusting for inflation, currency, and commodity volatility
- Setting stretch targets without killing innovation
- Using voice-of-customer data to align cost with perceived value
- Validating target cost assumptions using focus groups and conjoint analysis
- Creating a dynamic target cost dashboard for tracking
Module 3: The Design to Cost Framework and Process Flow - Overview of the 7-phase Design to Cost lifecycle
- Integration with stage-gate and agile product development
- Key decision points for cost validation in each phase
- Defining cross-functional ownership of cost outcomes
- Setting up Design to Cost gates in your innovation funnel
- Aligning technical reviews with financial checkpoints
- Creating a Design to Cost charter for your project
- Introducing the Design to Cost playbook
- Using cost-phase mapping to prevent late-stage changes
- Case study: Managing cost gates in a hybrid EV powertrain project
Module 4: Cost Modelling and Estimation Techniques - Bottom-up vs top-down cost models: when to use each
- Creating parametric cost models based on geometry and materials
- Using process-based costing for manufacturing operations
- Estimating material costs using current commodity indices
- Labour cost estimation by region and skill level
- Overhead allocation methods for R&D and indirect costs
- Building a bill-of-cost (BOC) alongside the bill-of-materials (BOM)
- Data sources for accurate cost inputs (public, internal, third-party)
- Validating estimates against historical builds and supplier quotes
- Managing uncertainty: confidence intervals and sensitivity analysis in cost models
Module 5: Target Cost Allocation and Decomposition - Breaking down system-level target cost to subsystems and components
- Allocation methods: functional, mass-based, value-based, and risk-weighted
- Using functional analysis to prioritise cost investment
- Creating a target cost waterfall chart
- Handling cost overruns at the subsystem level
- Balancing cost targets with reliability and performance targets
- Using design margins to buffer against cost uncertainty
- Managing trade-offs between cost, weight, and durability
- Interactive exercise: Allocate target cost for an electric scooter drivetrain
- Best practices for updating allocations during design evolution
Module 6: Design for Assembly and Manufacturability (DFAM) - How part count reduction drives cost and quality improvements
- Applying design simplification principles to mechanical systems
- Standardising components and fasteners across product lines
- Minimising handling, orientation, and insertion complexity
- Using assembly time estimation models (e.g. DFA index)
- Designing for high-volume automated production
- Leveraging modular design to reduce process variation
- Selecting manufacturing processes with built-in cost advantages
- Comparing casting, stamping, injection moulding, and additive trade-offs
- Case study: Reducing assembly steps in a diagnostic device by 60%
Module 7: Material and Process Optimisation - Selecting materials based on cost per unit function (e.g. strength per dollar)
- Alternatives to high-cost alloys and specialty plastics
- Using material substitution matrices for technical feasibility checks
- Life cycle cost analysis of material choices
- Sourcing strategies: domestic vs offshore, single vs dual sourcing
- Negotiating with suppliers using technical cost models
- Designing tolerances that match process capability
- Reducing scrap rate through robust design
- Lean principles in material usage and nesting efficiency
- Environmental and regulatory impact on material cost
Module 8: Cost Mapping and Design Margin Management - Visualising cost distribution across a product using heat maps
- Identifying cost outliers and hidden cost drivers
- Creating a cost responsibility matrix (CRM)
- Setting internal design cost margins to protect against overruns
- Differentiating between controllable and structural costs
- Tracking cost performance index (CPI) for design teams
- Using earned value concepts in product development
- Managing cost risk in prototype iterations
- Building cost transparency into daily engineering decisions
- Interactive exercise: Cost map a smart home thermostat assembly
Module 9: Value Engineering and Function Analysis - Applying Value Methodology (VM) in early design phases
- Conducting function analysis using FAST diagrams
- Distinguishing between necessary and secondary functions
- Identifying over-design and under-design in current products
- Using function-cost matrix to prioritise improvements
- Running cross-functional value analysis workshops
- Linking function performance to customer satisfaction metrics
- Generating creative alternatives using structured brainstorming
- Validating function-cost balance through customer testing
- Case study: Improving battery life while reducing bill-of-materials cost
Module 10: Tolerance and Quality Cost Optimisation - Understanding the cost of variation in manufacturing
- Linking tolerance specifications to process capability (Cp/Cpk)
- Using tolerance stack-up analysis to avoid over-constraining
- Applying Taguchi loss function to quantify quality cost
- Reducing inspection burden through robust design
- Designing controls for common cause vs special cause variation
- Linking reliability goals to warranty cost predictions
- Using failure mode and effects analysis (FMEA) for cost avoidance
- Setting acceptable risk levels based on cost impact
- Standardising validation tests to reduce development cost
Module 11: Supplier Integration and Early Involvement - The role of suppliers as design partners in cost innovation
- Selecting suppliers based on technical capability and cost insight
- Setting up early supplier involvement (ESI) protocols
- Sharing target cost data without revealing IP
- Using competitive bid analysis to validate cost assumptions
- Managing supplier quote discrepancies with technical negotiation
- Building joint cost models with key vendors
- Managing global supplier cost creep due to logistics
- Negotiation tactics based on cost model transparency
- Case study: Co-developing a sensor module with a Tier 1 supplier
Module 12: Digital Tools and Cost Simulation - Overview of Design to Cost software platforms
- Using CAD-integrated cost estimation plugins
- Automated feature recognition for manufacturability scoring
- Simulation tools for thermal, stress, and flow analysis to prevent over-design
- Linking PLM systems to cost databases
- Creating digital twins for cost and performance validation
- Using AI-assisted cost suggestion engines
- Dashboarding cost KPIs for engineering leadership
- Version control for cost models and design iterations
- Exporting cost data for ERP and financial systems
Module 13: Advanced Cost Trade-off Analysis - Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Overview of the 7-phase Design to Cost lifecycle
- Integration with stage-gate and agile product development
- Key decision points for cost validation in each phase
- Defining cross-functional ownership of cost outcomes
- Setting up Design to Cost gates in your innovation funnel
- Aligning technical reviews with financial checkpoints
- Creating a Design to Cost charter for your project
- Introducing the Design to Cost playbook
- Using cost-phase mapping to prevent late-stage changes
- Case study: Managing cost gates in a hybrid EV powertrain project
Module 4: Cost Modelling and Estimation Techniques - Bottom-up vs top-down cost models: when to use each
- Creating parametric cost models based on geometry and materials
- Using process-based costing for manufacturing operations
- Estimating material costs using current commodity indices
- Labour cost estimation by region and skill level
- Overhead allocation methods for R&D and indirect costs
- Building a bill-of-cost (BOC) alongside the bill-of-materials (BOM)
- Data sources for accurate cost inputs (public, internal, third-party)
- Validating estimates against historical builds and supplier quotes
- Managing uncertainty: confidence intervals and sensitivity analysis in cost models
Module 5: Target Cost Allocation and Decomposition - Breaking down system-level target cost to subsystems and components
- Allocation methods: functional, mass-based, value-based, and risk-weighted
- Using functional analysis to prioritise cost investment
- Creating a target cost waterfall chart
- Handling cost overruns at the subsystem level
- Balancing cost targets with reliability and performance targets
- Using design margins to buffer against cost uncertainty
- Managing trade-offs between cost, weight, and durability
- Interactive exercise: Allocate target cost for an electric scooter drivetrain
- Best practices for updating allocations during design evolution
Module 6: Design for Assembly and Manufacturability (DFAM) - How part count reduction drives cost and quality improvements
- Applying design simplification principles to mechanical systems
- Standardising components and fasteners across product lines
- Minimising handling, orientation, and insertion complexity
- Using assembly time estimation models (e.g. DFA index)
- Designing for high-volume automated production
- Leveraging modular design to reduce process variation
- Selecting manufacturing processes with built-in cost advantages
- Comparing casting, stamping, injection moulding, and additive trade-offs
- Case study: Reducing assembly steps in a diagnostic device by 60%
Module 7: Material and Process Optimisation - Selecting materials based on cost per unit function (e.g. strength per dollar)
- Alternatives to high-cost alloys and specialty plastics
- Using material substitution matrices for technical feasibility checks
- Life cycle cost analysis of material choices
- Sourcing strategies: domestic vs offshore, single vs dual sourcing
- Negotiating with suppliers using technical cost models
- Designing tolerances that match process capability
- Reducing scrap rate through robust design
- Lean principles in material usage and nesting efficiency
- Environmental and regulatory impact on material cost
Module 8: Cost Mapping and Design Margin Management - Visualising cost distribution across a product using heat maps
- Identifying cost outliers and hidden cost drivers
- Creating a cost responsibility matrix (CRM)
- Setting internal design cost margins to protect against overruns
- Differentiating between controllable and structural costs
- Tracking cost performance index (CPI) for design teams
- Using earned value concepts in product development
- Managing cost risk in prototype iterations
- Building cost transparency into daily engineering decisions
- Interactive exercise: Cost map a smart home thermostat assembly
Module 9: Value Engineering and Function Analysis - Applying Value Methodology (VM) in early design phases
- Conducting function analysis using FAST diagrams
- Distinguishing between necessary and secondary functions
- Identifying over-design and under-design in current products
- Using function-cost matrix to prioritise improvements
- Running cross-functional value analysis workshops
- Linking function performance to customer satisfaction metrics
- Generating creative alternatives using structured brainstorming
- Validating function-cost balance through customer testing
- Case study: Improving battery life while reducing bill-of-materials cost
Module 10: Tolerance and Quality Cost Optimisation - Understanding the cost of variation in manufacturing
- Linking tolerance specifications to process capability (Cp/Cpk)
- Using tolerance stack-up analysis to avoid over-constraining
- Applying Taguchi loss function to quantify quality cost
- Reducing inspection burden through robust design
- Designing controls for common cause vs special cause variation
- Linking reliability goals to warranty cost predictions
- Using failure mode and effects analysis (FMEA) for cost avoidance
- Setting acceptable risk levels based on cost impact
- Standardising validation tests to reduce development cost
Module 11: Supplier Integration and Early Involvement - The role of suppliers as design partners in cost innovation
- Selecting suppliers based on technical capability and cost insight
- Setting up early supplier involvement (ESI) protocols
- Sharing target cost data without revealing IP
- Using competitive bid analysis to validate cost assumptions
- Managing supplier quote discrepancies with technical negotiation
- Building joint cost models with key vendors
- Managing global supplier cost creep due to logistics
- Negotiation tactics based on cost model transparency
- Case study: Co-developing a sensor module with a Tier 1 supplier
Module 12: Digital Tools and Cost Simulation - Overview of Design to Cost software platforms
- Using CAD-integrated cost estimation plugins
- Automated feature recognition for manufacturability scoring
- Simulation tools for thermal, stress, and flow analysis to prevent over-design
- Linking PLM systems to cost databases
- Creating digital twins for cost and performance validation
- Using AI-assisted cost suggestion engines
- Dashboarding cost KPIs for engineering leadership
- Version control for cost models and design iterations
- Exporting cost data for ERP and financial systems
Module 13: Advanced Cost Trade-off Analysis - Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Breaking down system-level target cost to subsystems and components
- Allocation methods: functional, mass-based, value-based, and risk-weighted
- Using functional analysis to prioritise cost investment
- Creating a target cost waterfall chart
- Handling cost overruns at the subsystem level
- Balancing cost targets with reliability and performance targets
- Using design margins to buffer against cost uncertainty
- Managing trade-offs between cost, weight, and durability
- Interactive exercise: Allocate target cost for an electric scooter drivetrain
- Best practices for updating allocations during design evolution
Module 6: Design for Assembly and Manufacturability (DFAM) - How part count reduction drives cost and quality improvements
- Applying design simplification principles to mechanical systems
- Standardising components and fasteners across product lines
- Minimising handling, orientation, and insertion complexity
- Using assembly time estimation models (e.g. DFA index)
- Designing for high-volume automated production
- Leveraging modular design to reduce process variation
- Selecting manufacturing processes with built-in cost advantages
- Comparing casting, stamping, injection moulding, and additive trade-offs
- Case study: Reducing assembly steps in a diagnostic device by 60%
Module 7: Material and Process Optimisation - Selecting materials based on cost per unit function (e.g. strength per dollar)
- Alternatives to high-cost alloys and specialty plastics
- Using material substitution matrices for technical feasibility checks
- Life cycle cost analysis of material choices
- Sourcing strategies: domestic vs offshore, single vs dual sourcing
- Negotiating with suppliers using technical cost models
- Designing tolerances that match process capability
- Reducing scrap rate through robust design
- Lean principles in material usage and nesting efficiency
- Environmental and regulatory impact on material cost
Module 8: Cost Mapping and Design Margin Management - Visualising cost distribution across a product using heat maps
- Identifying cost outliers and hidden cost drivers
- Creating a cost responsibility matrix (CRM)
- Setting internal design cost margins to protect against overruns
- Differentiating between controllable and structural costs
- Tracking cost performance index (CPI) for design teams
- Using earned value concepts in product development
- Managing cost risk in prototype iterations
- Building cost transparency into daily engineering decisions
- Interactive exercise: Cost map a smart home thermostat assembly
Module 9: Value Engineering and Function Analysis - Applying Value Methodology (VM) in early design phases
- Conducting function analysis using FAST diagrams
- Distinguishing between necessary and secondary functions
- Identifying over-design and under-design in current products
- Using function-cost matrix to prioritise improvements
- Running cross-functional value analysis workshops
- Linking function performance to customer satisfaction metrics
- Generating creative alternatives using structured brainstorming
- Validating function-cost balance through customer testing
- Case study: Improving battery life while reducing bill-of-materials cost
Module 10: Tolerance and Quality Cost Optimisation - Understanding the cost of variation in manufacturing
- Linking tolerance specifications to process capability (Cp/Cpk)
- Using tolerance stack-up analysis to avoid over-constraining
- Applying Taguchi loss function to quantify quality cost
- Reducing inspection burden through robust design
- Designing controls for common cause vs special cause variation
- Linking reliability goals to warranty cost predictions
- Using failure mode and effects analysis (FMEA) for cost avoidance
- Setting acceptable risk levels based on cost impact
- Standardising validation tests to reduce development cost
Module 11: Supplier Integration and Early Involvement - The role of suppliers as design partners in cost innovation
- Selecting suppliers based on technical capability and cost insight
- Setting up early supplier involvement (ESI) protocols
- Sharing target cost data without revealing IP
- Using competitive bid analysis to validate cost assumptions
- Managing supplier quote discrepancies with technical negotiation
- Building joint cost models with key vendors
- Managing global supplier cost creep due to logistics
- Negotiation tactics based on cost model transparency
- Case study: Co-developing a sensor module with a Tier 1 supplier
Module 12: Digital Tools and Cost Simulation - Overview of Design to Cost software platforms
- Using CAD-integrated cost estimation plugins
- Automated feature recognition for manufacturability scoring
- Simulation tools for thermal, stress, and flow analysis to prevent over-design
- Linking PLM systems to cost databases
- Creating digital twins for cost and performance validation
- Using AI-assisted cost suggestion engines
- Dashboarding cost KPIs for engineering leadership
- Version control for cost models and design iterations
- Exporting cost data for ERP and financial systems
Module 13: Advanced Cost Trade-off Analysis - Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Selecting materials based on cost per unit function (e.g. strength per dollar)
- Alternatives to high-cost alloys and specialty plastics
- Using material substitution matrices for technical feasibility checks
- Life cycle cost analysis of material choices
- Sourcing strategies: domestic vs offshore, single vs dual sourcing
- Negotiating with suppliers using technical cost models
- Designing tolerances that match process capability
- Reducing scrap rate through robust design
- Lean principles in material usage and nesting efficiency
- Environmental and regulatory impact on material cost
Module 8: Cost Mapping and Design Margin Management - Visualising cost distribution across a product using heat maps
- Identifying cost outliers and hidden cost drivers
- Creating a cost responsibility matrix (CRM)
- Setting internal design cost margins to protect against overruns
- Differentiating between controllable and structural costs
- Tracking cost performance index (CPI) for design teams
- Using earned value concepts in product development
- Managing cost risk in prototype iterations
- Building cost transparency into daily engineering decisions
- Interactive exercise: Cost map a smart home thermostat assembly
Module 9: Value Engineering and Function Analysis - Applying Value Methodology (VM) in early design phases
- Conducting function analysis using FAST diagrams
- Distinguishing between necessary and secondary functions
- Identifying over-design and under-design in current products
- Using function-cost matrix to prioritise improvements
- Running cross-functional value analysis workshops
- Linking function performance to customer satisfaction metrics
- Generating creative alternatives using structured brainstorming
- Validating function-cost balance through customer testing
- Case study: Improving battery life while reducing bill-of-materials cost
Module 10: Tolerance and Quality Cost Optimisation - Understanding the cost of variation in manufacturing
- Linking tolerance specifications to process capability (Cp/Cpk)
- Using tolerance stack-up analysis to avoid over-constraining
- Applying Taguchi loss function to quantify quality cost
- Reducing inspection burden through robust design
- Designing controls for common cause vs special cause variation
- Linking reliability goals to warranty cost predictions
- Using failure mode and effects analysis (FMEA) for cost avoidance
- Setting acceptable risk levels based on cost impact
- Standardising validation tests to reduce development cost
Module 11: Supplier Integration and Early Involvement - The role of suppliers as design partners in cost innovation
- Selecting suppliers based on technical capability and cost insight
- Setting up early supplier involvement (ESI) protocols
- Sharing target cost data without revealing IP
- Using competitive bid analysis to validate cost assumptions
- Managing supplier quote discrepancies with technical negotiation
- Building joint cost models with key vendors
- Managing global supplier cost creep due to logistics
- Negotiation tactics based on cost model transparency
- Case study: Co-developing a sensor module with a Tier 1 supplier
Module 12: Digital Tools and Cost Simulation - Overview of Design to Cost software platforms
- Using CAD-integrated cost estimation plugins
- Automated feature recognition for manufacturability scoring
- Simulation tools for thermal, stress, and flow analysis to prevent over-design
- Linking PLM systems to cost databases
- Creating digital twins for cost and performance validation
- Using AI-assisted cost suggestion engines
- Dashboarding cost KPIs for engineering leadership
- Version control for cost models and design iterations
- Exporting cost data for ERP and financial systems
Module 13: Advanced Cost Trade-off Analysis - Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Applying Value Methodology (VM) in early design phases
- Conducting function analysis using FAST diagrams
- Distinguishing between necessary and secondary functions
- Identifying over-design and under-design in current products
- Using function-cost matrix to prioritise improvements
- Running cross-functional value analysis workshops
- Linking function performance to customer satisfaction metrics
- Generating creative alternatives using structured brainstorming
- Validating function-cost balance through customer testing
- Case study: Improving battery life while reducing bill-of-materials cost
Module 10: Tolerance and Quality Cost Optimisation - Understanding the cost of variation in manufacturing
- Linking tolerance specifications to process capability (Cp/Cpk)
- Using tolerance stack-up analysis to avoid over-constraining
- Applying Taguchi loss function to quantify quality cost
- Reducing inspection burden through robust design
- Designing controls for common cause vs special cause variation
- Linking reliability goals to warranty cost predictions
- Using failure mode and effects analysis (FMEA) for cost avoidance
- Setting acceptable risk levels based on cost impact
- Standardising validation tests to reduce development cost
Module 11: Supplier Integration and Early Involvement - The role of suppliers as design partners in cost innovation
- Selecting suppliers based on technical capability and cost insight
- Setting up early supplier involvement (ESI) protocols
- Sharing target cost data without revealing IP
- Using competitive bid analysis to validate cost assumptions
- Managing supplier quote discrepancies with technical negotiation
- Building joint cost models with key vendors
- Managing global supplier cost creep due to logistics
- Negotiation tactics based on cost model transparency
- Case study: Co-developing a sensor module with a Tier 1 supplier
Module 12: Digital Tools and Cost Simulation - Overview of Design to Cost software platforms
- Using CAD-integrated cost estimation plugins
- Automated feature recognition for manufacturability scoring
- Simulation tools for thermal, stress, and flow analysis to prevent over-design
- Linking PLM systems to cost databases
- Creating digital twins for cost and performance validation
- Using AI-assisted cost suggestion engines
- Dashboarding cost KPIs for engineering leadership
- Version control for cost models and design iterations
- Exporting cost data for ERP and financial systems
Module 13: Advanced Cost Trade-off Analysis - Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- The role of suppliers as design partners in cost innovation
- Selecting suppliers based on technical capability and cost insight
- Setting up early supplier involvement (ESI) protocols
- Sharing target cost data without revealing IP
- Using competitive bid analysis to validate cost assumptions
- Managing supplier quote discrepancies with technical negotiation
- Building joint cost models with key vendors
- Managing global supplier cost creep due to logistics
- Negotiation tactics based on cost model transparency
- Case study: Co-developing a sensor module with a Tier 1 supplier
Module 12: Digital Tools and Cost Simulation - Overview of Design to Cost software platforms
- Using CAD-integrated cost estimation plugins
- Automated feature recognition for manufacturability scoring
- Simulation tools for thermal, stress, and flow analysis to prevent over-design
- Linking PLM systems to cost databases
- Creating digital twins for cost and performance validation
- Using AI-assisted cost suggestion engines
- Dashboarding cost KPIs for engineering leadership
- Version control for cost models and design iterations
- Exporting cost data for ERP and financial systems
Module 13: Advanced Cost Trade-off Analysis - Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Multi-criteria decision analysis (MCDA) for design choices
- Building decision matrices that weight cost, risk, performance, and time
- Using Pugh matrices to evaluate concept alternatives
- Scenario planning for cost sensitivity to material price swings
- Trade-off curves: cost vs weight, cost vs power, cost vs durability
- Optimising design for total cost of ownership (TCO)
- Incorporating sustainability targets into cost models
- Managing regulatory compliance cost across regions
- Case study: Balancing battery size, range, and cost in an EV
- Interactive exercise: Evaluate 3 motor design options using trade-off analysis
Module 14: Cost-Driven Innovation and Platform Strategy - Using cost constraints to fuel creative breakthroughs
- Developing product platforms with shared cost architecture
- Scaling variants without proportional cost increases
- Designing for upgradability and field service cost reduction
- Extending product life through modular refurbishment
- Creating cost-competitive entry-level versions without cannibalising premium
- Using architecture diagrams to manage cost inheritance
- Freezing platform elements early to control cost drift
- Case study: Building a scalable appliance platform across 5 market tiers
- Measuring innovation ROI using cost-performance ratio
Module 15: Managing the Cost Review Process - Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Structuring formal cost review meetings with cross-functional teams
- Creating cost review checklists and scorecards
- Presenting cost data in ways that resonate with executives
- Handling resistance from engineering or marketing teams
- Linking cost reviews to project risk assessments
- Digital collaboration tools for virtual cost reviews
- Documenting decisions and rationale for audit purposes
- Setting up cost review escalation paths
- Using pre-mortems to anticipate cost-related project failures
- Case study: Conducting a virtual global cost review for a medical device
Module 16: Cost Communication and Stakeholder Alignment - Talking about cost with non-financial team members
- Translating cost data into business impact stories
- Creating cost dashboards for different audiences (execs, engineers, finance)
- Using visual storytelling to show cost evolution over time
- Preparing executive summaries of cost performance
- Aligning R&D incentives with cost targets
- Building credibility as a cost-aware technical leader
- Managing political dynamics in cost discussions
- Training your team on cost awareness principles
- Case study: Winning board approval for a new product line with a cost impact narrative
Module 17: Integration with Lean Product Development - Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup
Module 18: Certification Project and Real-World Application - Overview of the certification project requirements
- Selecting a real or hypothetical product for cost optimisation
- Defining project scope, stakeholders, and success criteria
- Conducting a baseline cost assessment
- Applying all 17 modules’ tools to your project
- Creating a target cost allocation map
- Performing value analysis and function-cost evaluation
- Developing a cost-optimised design proposal
- Building a business case showing cost savings and competitive advantage
- Submitting your project for review and earning your Certificate of Completion by The Art of Service
- Mapping Design to Cost to lean principles (eliminate waste, flow, pull)
- Reducing over-processing and over-design as forms of waste
- Shortening lead time through concurrent cost analysis
- Using set-based design to explore cost-optimised solution spaces
- Reducing rework by catching cost issues early
- Applying lean metrics to design efficiency (e.g. value-added time %)
- Creating standard work for cost estimation tasks
- Building continuous improvement into cost management
- Linking Design to Cost to overall product development agility
- Case study: Applying lean cost practices in an agile hardware startup