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... as you all remember, our previous model used a three-piece injection molded housing which required 12 screws in assembly. This defined our per unit cost more than anything, due to the extra labor involved (relaxed Indonesian labor law notwithstanding). Now, what we came up with is this fourth case component, which exploits existing topographical features in the other components, to join them with a system of interlocking tabs, rather than screws. Using this design, we were able to eliminate ten screws from the unit assembly process, reducing our labor requirements significantly. Jim and I project that with this design, we’ll be able to lay off 30% of the Indonesia plant immediately. After factoring in the cost of the new case elements, that staff reduction translates to a 14% reduction in per-unit cost.
