Project background
To make hydroponics accessible in emerging markets, the client needed a radically cost-reduced version of an existing system without compromising reliability. Every component, vendor, and assembly step was on the table.
Challenge
Hitting an aggressive target cost while keeping spare-parts availability realistic for local service. Eliminating proprietary parts where possible and redesigning the BOM around components available through multiple vendors.
Approach & solution
We ran a full DFM pass: consolidating parts, replacing specialty components with locally available equivalents, and converting fabricated parts to molded or stamped alternatives where volumes justified it. Assembly sequence was re-planned for non-specialist labor, and a field-service kit was defined.
Results & benefits
Unit cost dropped substantially versus the original design, unlocking new markets for the client. Assembly time decreased, and field service became feasible with commonly available tools and spares.
