Value Engineering: Automotive Control Unit

Our Brief

Maintaining the integrity of the original product would be tough. We’d need to makes sure the circuitry stayed as close to the original layout as possible.

And as well as following design rules, the connectors and mechanical features had to be in exactly the same place.

Fortunately, the client had Gerber files, a PDF of the schematic, and BOM files. So, equipped with these, we set our minds to the job.

Our Approach

First off, we developed, checked and approved the CAD models before designing the new schematic.

After replicating the old placement and routing patterns by importing the Gerber files, we used these as a template. 

Once complete, we made sure differences were minimal by exporting the new Gerber files and comparing these against the originals.

As soon as we were satisfied with the results, we implemented the new part on the schematic and PCB.

The Results 

Thanks to our meticulous approach, our client rapidly re-created their ‘hero’ control unit. As well as extending product life, this maintained revenue for servicing and spare parts.

Re-using approved designs and extending product life, the client made significant cost savings in development and manufacturing.

And through hiring specialist expertise, they avoided additional overheads - hiring extra staff or overloading internal resources. Leaving them to focus on core business activities.