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In the world of automotive engineering, where design complexity often grows with the ambition of each team, it’s easy for costs to balloon unnoticed. Yet, as the expert team at Munro & Associates regularly demonstrates, even minor design decisions can lead to massive savings—or unnecessary expense. This is where a cost-saving automotive design review from Munro makes all the difference.
A recent Munro teardown illustrates this through a powerful, relatable case study. By dissecting a glove box assembly from a 1961 vehicle, the team reveals how misaligned engineering decisions can quietly erode profits—unless caught early by experienced consultants who understand both design and manufacturing realities.
When Best Practices Collide: A Glove Box Cautionary Tale
To keep the discussion confidential yet illustrative, Munro used components from one of their own vintage vehicles. The story unfolds around three fictional engineers—Bob, Jerry, and “the new guy”—each an expert in a different field: injection molding, casting, and problem-solving assembly, respectively.
Bob, the injection molding expert, designs the glove box door with a hinge pin mounted high for durability—an ideal decision within the realm of molded plastics. Jerry, the casting expert, creates side brackets with deep channels to protect against structural failure, again aligning with best practices for cast parts. However, neither engineer speaks with the other during development.
Enter the new engineer. Seeking to bridge the gap between two rigidly correct yet incompatible components, he adds a third piece: a stamped metal bracket featuring a riveted pin and a force-fit nut. This clever workaround impresses management and engineers alike—until the costs are added up.
Design Guidelines vs. System Integration
On paper, each part meets internal engineering standards. But when integrated, the assembly becomes an over-engineered, labor-intensive patchwork—what Munro compares to a Rube Goldberg machine. The clever fix, though functional, introduces multiple parts, added labor, and a higher potential for assembly errors.
The crux of the issue? Siloed thinking. Each engineer optimized for their own discipline, rather than for the system as a whole. Only a teardown and automotive design review by a third party like Munro can expose how these “correct” decisions, without cost-saving oversight, collectively form an inefficient system.
The Engineering Economics of a Small Part
To quantify the impact, Munro calculated the cost difference of the overcomplicated solution versus a simplified revision implemented in 1961. The original design featured separate stampings, bolts, rivets, and labor-intensive assembly steps. The revised version replaced multiple components with a single integrated piece.
Here’s the breakdown:
- Original system cost per vehicle (2 parts): $2.50
- Annual vehicle production: 100,000 units
- Annual added cost: $250,000
- Over 7 years (common platform lifecycle): $1.75 million
That’s nearly two million dollars saved by simplifying a bracket. And it’s just one part on one subsystem. Multiply that insight across a full vehicle, and the stakes become enormous.
Quality Issues Compound Cost
Beyond raw material and labor costs, the original design introduced quality risks. As Munro points out, parts that can be assembled incorrectly often will be. Misaligned brackets, loose rivets, or reversed stampings increase the likelihood of defects—driving warranty costs, rework, and brand damage.
For example, the original glove box ribbing, intended as an anti-rotation feature, failed to prevent motion over time. This led to wear and eventual failure—problems not obvious at the CAD stage but glaring during real-world use.
Changing a Design Mid-Production: Lessons Learned
By March 1961, the OEM made key changes:
- Repositioned the pin to a more direct mounting location
- Integrated the tab previously bolted on, into the main casting
These simple moves eliminated unnecessary processes and materials. However, the tooling and assembly investments for the original design had already been made. While improvements cut future costs, some losses were unrecoverable—a reminder that early consultation pays the highest dividends.
Munro’s Role: Navigating Politics and Process
A recurring theme in Munro’s teardown consulting work is navigating internal resistance. Engineers often stick to familiar practices to avoid blame. As Sandy Munro’s team notes, “If Bob had put his pin in a different spot and something failed, management would blame Bob.”
Here, Munro acts as a shield and translator—working with engineers and managers alike to advocate for better design without triggering fear or finger-pointing. Their job isn’t to embarrass but to improve, backed by data, examples, and deep manufacturing expertise.
When to Call Munro: Before It Costs You
One of the key takeaways from this story is timing. Some clients approach Munro before production tooling is finalized, allowing room to optimize without sunk costs. Others wait until defects, cost overruns, or inefficiencies force a redesign.
While Munro excels at both reactive and proactive consulting, the biggest savings come from early engagement—especially in areas that seem minor. After all, a small bracket may only cost $1.25 each, but at scale, it represents a million-dollar difference.
Real Value in the Details
The glove box case is emblematic of the design culture Munro helps companies evolve. It’s not about flashy innovation or complex mechanisms. It’s about results—practical, manufacturable solutions that reduce cost, improve quality, and enhance vehicle performance. Munro’s expertise helps companies:
- Evaluate and optimize existing parts
- Identify unnecessary complexity
- Cut redundant materials and processes
- Improve manufacturability
- Present clear data to justify design changes
Partner with Munro for Smarter Designs
If your team is preparing for production—or already struggling with high cost-of-goods and quality issues—Munro’s design review can uncover the hidden inefficiencies eating into your margins. Whether it’s a single part or a full vehicle platform, Munro’s cost-saving automotive design review can yield exponential returns.
Explore more teardown insights, cost breakdowns, and engineering reviews at Munro & Associates. Contact us to schedule a consultation and see how much your next decision could save.