Evaluating Product Redesign Requirements for Reshoring Success

Reshoring manufacturing operations is an opportunity for companies to modernize and strengthen their production processes.

The most critical step in this transition is evaluating whether products originally designed for overseas manufacturing are suitable for domestic production. This often requires significant redesigns to align with local manufacturing capabilities, labor costs, and advanced automation technologies.

At Boston Engineering, we specialize in product development and design for manufacturability, helping companies transition to re-shored production without compromising quality or efficiency..

In this blog, we discuss detailed examples of how to evaluate product redesign requirements and how we can assist in this vital process. 

Continue reading below to learn more

Download "Re-Shoring and Supply Chain Disruption" from Boston Engineering

Impacts and Strategic Responses from the Boston Engineering founders. Whether you’re facing workforce shortages, navigating policy changes, or striving to modernize your operations, this conversation offers concrete solutions to tackle today’s challenges and position your business for long-term success.

The re-shoring trend is transforming the way product companies think about their supply chains and manufacturing strategies. What began as a response to rising labor costs and geopolitical risks has accelerated in the wake of the pandemic, revealing vulnerabilities in global supply chains and prompting companies to reevaluate their sourcing, production, and distribution models.

Download "Re-Shoring and Supply Chain Disruption" from Boston Engineering

In this interview, Boston Engineering’s founders, Mark Smithers (Chief Technology Officer) and Bob Treiber (President), share insights into the key drivers behind re-shoring, the real-world challenges, and how companies can adapt to take advantage of the changes.

Drawing from decades of experience in defense, medical, and commercial sectors, they explore the practical implications of re-shoring for operations executives, product managers, and C-suite leaders alike.

Download "Re-Shoring and Supply Chain Disruption" from Boston Engineering

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Why Product Redesign is Essential for Reshoring

Products designed for offshore manufacturing often rely on labor-intensive processes and materials that may not align with domestic production models. Without redesign, companies risk inefficiencies, increased costs, or production delays. Evaluating and optimizing product designs ensures that reshoring delivers the intended benefits, such as cost savings, improved quality, and faster lead times. 

Potential Evaluation Steps:

Automation is a cornerstone of cost-effective domestic manufacturing. Products need to be evaluated for their compatibility with automated processes. 

A consumer electronics company reshoring its assembly line discovers that its products require numerous manual steps, which are cost-prohibitive in the U.S. These steps could be streamlined through redesign for robotic assembly. 

Key Questions: 

• Can the product design accommodate automation tools like robotics or AI-driven machinery? 

• Are there components that can be simplified or combined to reduce manual labor? 

Engineering and Design Tools to consider: 

• Conduct product design assessments to identify opportunities for automation. 

• Use digital twins to simulate automated production processes and pinpoint inefficiencies. 

• Redesign products with features that facilitate robotic assembly, such as snap-fit components or fewer assembly steps. 

2. Simplifying Design for Manufacturability (DFM) 

Domestic manufacturing often requires simplifying product designs to reduce production complexity and costs. 

A medical device manufacturer relies on complex assemblies requiring precise manual adjustments during production. Redesigning the product for manufacturability enables the use of standardized components and automated calibration processes. 

Key Questions: 

• Can the product design be simplified to reduce material costs and assembly time? 

• Are there opportunities to use standardized or locally sourced components? 

Engineering and Design Tools to consider: 

• Apply Design for Manufacturability (DFM) principles to optimize product designs. 

• Evaluate material choices to ensure availability and cost-efficiency with local suppliers. 

• Redesign products to reduce the number of parts and simplify assembly processes. 

3. Ensuring Compliance with Domestic Standards 

Products manufactured in the U.S. must adhere to strict regulatory and quality standards, particularly in industries like medical devices, aerospace, and defense. 

A defense contractor transitioning to domestic manufacturing discovers that certain materials used in offshore production do not meet U.S. compliance standards. Redesigning the product with compliant materials ensures regulatory approval. 

Key Questions: 

• Do the materials and components used in the current design meet domestic compliance requirements? 

• Are additional quality assurance or testing processes required? 

Engineering and Design Tools to consider: 

• Evaluate product designs for compliance with domestic regulatory standards, such as FDA or DoD requirements. 

• Redesign products using certified materials and processes that meet U.S. regulations. 

• Implement robust testing protocols to ensure quality and compliance throughout production. 

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4. Aligning with Local Manufacturing Capabilities 

Domestic facilities may have different capabilities compared to overseas operations, requiring adjustments in product design. 

An automotive parts manufacturer discovers that U.S. suppliers use different manufacturing techniques, such as injection molding instead of manual welding. Redesigning components ensures compatibility with local capabilities. 

Key Questions: 

• Are the current product designs aligned with domestic manufacturing processes and equipment? 

• Do local suppliers have the capacity and expertise to produce the required components? 

Engineering and Design Tools to consider:

• Conduct capability assessments of domestic suppliers and manufacturing facilities. 

• Redesign products to leverage available local manufacturing technologies. 

• Collaborate with suppliers to ensure seamless integration of redesigned components into production lines. 

5. Using Advanced Tools for Redesign 

Modern technologies can streamline the redesign process and reduce the time to market for re-shored products. 

A medical device company uses digital twins to model and test design changes virtually, eliminating the need for costly physical prototypes. 

Key Tools: 

• Digital Twins: Simulate production processes to optimize designs for efficiency and cost-effectiveness. 

• AI-Driven Design: Analyze data to identify potential improvements and predict performance outcomes. 

• 3D Printing: Rapidly prototype redesigned components to validate form, fit, and function. 

Engineering and Design Tools to consider: 

• Use digital twins to test multiple redesign scenarios and identify the most effective solution. 

• Leverage 3D printing for rapid prototyping and iterative testing. 

• Apply AI-driven tools to optimize designs for performance, quality, and manufacturability. 

Why Choose Boston Engineering? 

At Boston Engineering, we don’t just solve problems—we create opportunities. Reshoring is a complex process, but it also opens doors for innovation and long-term growth. 

By partnering with us, you gain access to: 

• Expert product redesign: Align your products with domestic manufacturing capabilities. 

• Advanced supply chain solutions: Navigate the complexities of localization with ease. 

• Workforce empowerment: Equip your team with the tools and training they need to succeed. 

• Infrastructure modernization: Transform your facilities with cutting-edge technologies. 

• Strategic planning: Build a roadmap for reshoring that ensures resilience and scalability. 

At Boston Engineering, we provide comprehensive support for businesses facing reshoring decisions. Our expertise includes:

• Supply Chain Audits: Identifying inefficiencies and risks in product level supply chains.
• Product Redesign: Optimizing products for domestic manufacturing and automation.
• Technology Integration: Leveraging tools like digital twins and AI to model scenarios and streamline processes.
• Strategic Planning: Building actionable roadmaps that align with your goals and ensure long-term success.

Boston Engineering: Your Partner in Reshoring Success 

Product redesign is a critical step in reshoring that ensures compatibility with domestic manufacturing, reduces costs, and enhances efficiency. By conducting a thorough evaluation and leveraging advanced tools, companies can unlock the full potential of reshored production. 

At Boston Engineering, we specialize in guiding businesses through this process, offering tailored solutions that align with your goals and capabilities. 

Let’s work together to shape the future of American manufacturing—one innovative solution at a time. 

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