NPI, DFM/DFA & Engineering Change worked example

Part Count Reduction Savings at 86% share of theoretical savings actually captured: a worked example

This scenario runs the part count reduction savings calculation on the strong side: 86% share of theoretical savings actually captured, with every other input held at its documented default. a DFA engineer needs to justify a consolidation redesign by quantifying savings from fewer parts.

The inputs for this scenario

  • Parts eliminated from the assembly: 8 parts (unchanged)
  • Fully-loaded annual cost carried per part: 6.5 $ / part (unchanged)
  • Share of theoretical savings actually captured: 86 % (raised for this scenario; the documented default is 75)
  • One-time redesign engineering cost: -3,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Net savings = parts eliminated × cost carried per part × realized share − redesign engineering cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 44.72 $ for total part count reduction savings cost, the number this scenario is built around.
  • At this operating point the engine returns 5.59 $ / piece for part count reduction savings cost per unit.
  • At this operating point the engine returns 44.72 $ for variable part count reduction savings cost.
  • At this operating point the engine returns 0 $ for fixed part count reduction savings adder.

How this compares with the baseline

  • Against the tool's baseline example, where share of theoretical savings actually captured sits at 75% and the headline result is 39 $, this scenario comes in 14.67% above the baseline at 44.72 $.
  • Use it when justifying a DFA part-consolidation project or comparing competing redesign options on cost payoff. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total part count reduction savings cost: 44.72 $ (headline result)
  • Part count reduction savings cost per unit: 5.59 $ / piece
  • Variable part count reduction savings cost: 44.72 $
  • Fixed part count reduction savings adder: 0 $

Run it with your numbers

  • Every input above is editable in the live Part Count Reduction Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.