Fast Fact: Average ROI for Munro Customers is More than 10 Fold in One Year

Did you know that the average ROI for Munro customers is more than 10 fold in one year and the average payback period is just three months?

It’s true.

Since 1988, Munro & Associates has consistently saved companies billions of dollars spanning the gamut of manufacturing industries from aerospace, defense, automotive, marine, medical, heavy industries, MTDM, consumer electronics and more.

The company has a proven track record of helping companies reduce “time to market,” R&D, engineering and manufacturing costs, while increasing the quality of products, processes and systems. This has resulted in customers not only realizing higher profit margins, but also significantly increasing market share … or achieving market dominance.

How does Munro do it?

By evolving the way companies manufacture. From the executive level (program cost reduction and management, consolidation, risk assessment) down through engineering, costing, supply chain and manufacturing, Munro offers a suite of exclusive, time-tested tools and methodologies that are the envy of the industry.

Don’t just take our word for it. Click here and we’ll sent you a case study relevant to your industry:

Tearing Down Tesla: Comparing Secrets of Tesla and Other Leading EVs

Calling all automotive engineers looking for objective technical information about today’s leading electric vehicles (EVs).

This post kicks off a series of articles that will compare notable aspects of leading EVs. From OEM assembly time to suspension and from battery cooling systems to HVAC ducting and venting, this series will cover a lot of ground. Most importantly, it aims to offer knowledge that’s interesting and valuable to today’s engineers … with data points that support our findings.

We used our proprietary Design Profit software for all of our teardown analysis. It enables the teardown team to document each part, how it is installed in the vehicle, as well as how it’s assembled in each subassembly. With this data, we’re able to reverse engineer the assembly process for the given vehicle. More information about the software can be found here:

With that said, here’s the first post ….

Did you know that the BMW i3 has a serviceable battery pack while the Tesla Model 3 doesn’t?

Background: The BMW i3 has a serviceable battery that can be lowered from the vehicle by removing the pack’s mount bolts located on the exterior of vehicle. Individual sub-packs can be replaced after removal of the cover and sub-pack fasteners.

The Tesla Model 3 battery pack was designed not to be serviced. It requires the removal of bolts in the interior and exterior of the vehicle to drop out the battery pack, as well as the removal of the vehicle’s seats and carpeting (to access bolts). The battery pack uses structural adhesives to seal and mount its cover and sub-packs, which does not allow service to open and easily remove modules for repair.

Insight: The advantage of the Tesla Model 3 non-serviceable battery pack is that it reduces the final assembly cost of the battery pack. The disadvantage is that if significant cell damage happens in the pack, then it requires a full swap of the battery pack.

Side note: based on the range for the Tesla Model 3 battery pack vs the BMW i3, in order to equalize, the BMW i3 assembly costs would be considerably higher than the current cost analysis.

Data:  The Tesla Model 3 uses three lines of structure adhesive bead and 78 fasteners, with a final assembly cost of $36.87 to mount the sub-packs and install the battery pack cover. The BMW i3 battery pack uses 120 fasteners, with a final assembly cost of $41.39.

Munro on Tesla’s Motors: “They’ve Got Magic!”

After watching numerous interviews of Munro, it is apparent that it takes a lot to impress him, and Tesla does exactly that. When talking about Tesla’s innovation, he is as happy as a kid in a candy store. Like anyone, Munro wants to make money, but like many engineers, he is intrinsically obsessed with his work and you can tell he really loves this technology.”Kurt Lowder, CleanTechnica

Does anyone else remember when Sandy Munro said that Tesla’s motors have magic? If you missed it, this CleanTechnica article offers a nice recap of how Sandy explains Tesla’s motor magic.

According to the article, Tesla’s newer permanent magnet motors are superior to the competition for a number of reasons. This article focused on one of those reasons: magnets. Per the article:

“Tesla was able to take advantage of what is referred to as the Halbach array. Tesla’s new permanent magnet motors are an improved design that first appeared in the Model 3. Only recently have the Model S and Model X been upgraded to this new technology.

Magnets within these motors are engineered to create a more optimal magnetic field. Four carefully designed, small magnets that oppose each other are actually glued together to create a stronger — or rather, a more optimized — magnetic field that makes the permanent magnet motor more powerful and more efficient. There are several of these magnets within the motor.

This crucial aspect of the motor is one of the main reasons why Tesla vehicles get more range than competing vehicles that have the same size battery packs.”

Interested in learning more? Then head over to the full article with more details:

Now Available: Free Trial of Design Profit® Software

The holidays are coming early! You can now gain access to a free trial of the world-leading Design Profit® software. Test-drive the software that can take your product design, manufacturing and compliance process to new levels.

Wondering how Design Profit can help you?

The software gives your team the ability to peel away the onion of manufacturing and design complexity, so that issues of several types are identified before the design moves from engineering to the more expensive stages of prototype and finally manufacturing. Design Profit enables your team to creatively, analytically and visually map your prospective design so that it incorporates all aspects of variables and metrics sought by the combined team into one, easy to understand environment.

Want to get started? Complete this quick form to start your free trial process:

Announcing the Design Profit Newsletter

Design Profit is the world leading software company for innovating your product design, manufacturing and compliance process. Design Profit can take your product to new heights of creativity.

At Design Profit, we strive to create solutions to your manufacturing and design issues. As many companies have similar issues, we like to enhance your learning experience on this site by addressing some of the most common user questions.

Offering tips and tutorials, the Design Profit newsletter has six current issues:

Still have a question? Contact our support team for help:

Munro’s ‘Tesla Motor Mouths’ Featured in IndustryWeek

In a recent IndustryWeek article, Munro & Associates CEO Sandy Munro and Mark Ellis, senior lead design consultant, have a spirited discussion on electric vehicle drives.

Sandy also shared that, unasked, he also sent Elon Musk 230 ideas on how he could improve the build of the Model 3 and make it more realistic to manufacture. “I have no clue if he implemented any of it.” His motive was avuncular, he says—he wants Tesla to succeed because it’s the only automaker doing anything innovative.

Here are some other key takeaways from their interview:

  • If Sandy had to pick only one thing that distinguishes the Model 3 motor, which is the lightest of the four and has the most output, it would be the casing.
  • The magnets in the Tesla motor are “vastly different” than the other contenders.
  • The Tesla motor is also the cheapest … they think.
  • For car detectives, the Model 3 is the gift that keeps on giving.
  • When his colleague discovered the magnet configuration in the motor, Sandy got curious, took it over to a vice and gave it a tap with a hammer to see if he could break a magnet free. The whole thing exploded.
  • The BMW motor is the heaviest and most expensive, and it has the least amount of power.
  • Telsa’s invertor/convertor—the device that takes the battery power, and supplies that power to the electric motor—is very advanced.
  • Telsa’s the only automaker that uses silicon carbide on the integrated circuit (power supply) invertors.
  • Overall, Tesla’s motor is considerably smaller and more high-tech than the others.
  • The Tesla body, “looks like a kids’ high school project,” says Sandy.
  • The Model 3 battery design is “brilliant” in its circuitry design and how simple and lightweight it is compared to competitors, but there are issues with its manufacturing.
  • Overall, Tesla’s electronics team is “like a whole bunch of Sheldon Coopers that actually get along with people and don’t insult each other.”

Check out the full article for more details:

Munro Offers World’s First Official Lean Design® Certification Course

Are you ready to start your lean journey?

Munro & Associates is proud to offer the world’s first Lean Design Certification course, developed to teach the basics of the Lean Design® methodology, illustrate its value in the product design process and instill the student with an understanding of how to implement and execute the concepts through the Design Profit® software.

Lean Design® Certification Level One –  the first course of a five step training program to become Design Profit® certified –  demonstrates how the combined use of these tools and methodologies have the ability to influence and impact design cost, quality, weight, producibility and other important factors that affect the overall profit of a company.

Those interested in learning more about the only official Lean Design® Certification course, can find more information here:

What Can Design Profit Do for Your Company?

Design Profit has been responsible for saving companies billions of dollars over the past several decades.

Curious how the software can enhance your design?

A business case builder from Munro & Associates, Inc., Design Profit is the leading software in mapping, calculating and understanding your design goals from both a visual and metric based perspective. Design Profit collects data from the design, costing and manufacturing teams to create a comprehensive and predictive model that can easily be viewed and analyzed by engineering, manufacturing and executives alike in a visual product and process tool.

Check out this video to learn more:

Lean Design Book Available Now

Looking for a holiday gift for your favorite engineer?

Munro & Associates has an idea for you: the “Lean Design®: Value Quality Profit” book by Sandy Munro.

This book was created as a handbook to assist engineers in creating innovative, cost effective and high-quality products. Sandy and his editors have complied an easy-to-read, 160-page manual based on proven methods employed by Munro & Associates over the past 26 years across all industries.

Learn about critical lean design concepts, such as:

  • Munro’s Cornucopia of Profit;
  • The Munro Product Cycle;
  • Sandy’s philosophy on how and why companies need to change the rules to increase value, profit and quality;
  • The Ugly Baby Syndrome; and
  • Munro’s famous “Who Casts the Biggest Shadow” chart.

For more details or to purchase your copy, visit:

ICYMI: Sandy Munro Talks Tesla in China

Munro & Associates CEO Sandy Munro has talked about the Tesla Model 3 and his findings several times in the past, particularly when he’s featured as a guest on Autoline After Hours.

During his April Autoline appearance recapped here by Teslarati, Sandy discusses the Tesla’s China opportunities for the Model 3, as well as the rapid progress of large-scale construction projects such as Gigafactory 3. Munro also shared his frustration with some of analysts’ assumptions about Tesla.

“I found a new source of pain. Analysts, talking about things. Holy mackerel, where these guys get their ideas from, or where they get their information from is beyond me, but I can tell you one thing for sure. I know they didn’t tear apart one of these cars. I know they don’t really look at what it is that’s going on. I’m sure they’re good readers. Readers are leaders, but sometimes, they’re liars,” Munro noted.

Munro has experience with bad data. Emphasizing his point, the teardown expert stated that some of the assumptions being thrown about the company are flat-out untrue.

“Quite frankly, I’ve been on a few of these little shows and somebody says, ‘Well, you know, such-and-such from wherever says this.’ And I’m sitting there and going, ‘Ah, that’s not true.’ ‘Well, he said it was.’ I said ‘Oh, it’s not true.’ And then I’ll reach over like, I’ve got my books right over here. Somebody says something that I know is not true, I’ve got pictures, I’ve got numbers, I got data up the yin-yang. There’s nobody gonna argue with me, that’s for sure. And if I don’t know the answer, I got a whole 90 guys that’ll (be) happy to tell you which ends up. These other guys, I don’t know, I think it’s web searches and blogs and who knows, I don’t know. But it’s not for real,” Munro said.

Check out the April Autoline segment where Sandy shares more insight on Tesla: