66.5% off a key chip for a firework control device maker, and a BOM over 40% lower
A firework control device company doing over $30M a year was watching the cost of its PCB components and assembly climb, and getting few clear answers from its contract manufacturer in China. We went through its electronics BOM and cut the cost of key components, including a Texas Instruments chip at 66.5% below the DigiKey price the client compared against. With the board and assembly requoted too, the final BOM came in over 40% lower than its current electronics manufacturer.
- On a key TI chip
- −66.5%
- Lower BOM than the current CM
- 40%+
- Saved on the next run
- $168,000
- Client annual revenue
- $30M+
The challenge
Costs on PCB components and assembly kept rising, and communication with the contract manufacturer in China made it hard to find out why.
Where the savings came from
The biggest cuts came on key components. The Texas Instruments TPS2116DRLR is one of them: the same chip, sourced through our supplier network at 66.5% under the DigiKey price the client compared against.
Texas Instruments
TPS2116DRLR
A power switch that controls the power reaching the rest of the board.
- Up to 2.5 A
- 42 mΩ on-resistance
- SOT-583
−0.0%
Lower unit price, same part
$0.3846 saved per chip
$384.64 on every 1,000
DigiKey's cut tape price at 1,000 units, October 2026, the price the client compared against.
Across the full BOM: over 40% lower
Savings on the key components, the bare board and the assembly add up to a final BOM over 40% lower than the client's current electronics manufacturer.
Key components
Chips like the TPS2116DRLR
PCB
The bare board
PCBA
Assembling the finished board
What we did
- Went through the full electronics BOM, line by line
- Sourced key components through our supplier network, the TPS2116DRLR at 66.5% under DigiKey
- Requoted the bare PCB and the assembly
- Brought it all back as one quote for the finished board
The outcome
- 66.5% off the TPS2116DRLR, one of the key components
- A final BOM over 40% lower than the client's current electronics manufacturer
- $168,000 saved on the next manufacturing run, at the client's production volume
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