BOM optimization — lower cost and risk, without changing functionality
BOM (Bill of Materials) optimization is a review of the component list for availability, price and alternatives — without changing how the device works. We eliminate End of Life components, propose substitutes for hard-to-find parts and reduce the material cost of the order, keeping full compliance with the original design.
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What is BOM optimization and when is it worth doing?
The BOM (Bill of Materials) is the list of all components needed to assemble a device — with manufacturer part numbers, quantities and specifications. A once-approved design rarely returns to review, and the electronic component market changes faster than the project documentation.
The result: a BOM containing End of Life (EOL) components the manufacturer no longer produces, parts with long lead times due to market shortages, or items more expensive than available equivalents with identical parameters. Each of these problems leads to the same outcome — stopped production or squeezed margins.
BOM optimization is a systematic review of the component list: checking availability at distributors, identifying direct substitutes or those requiring a minor PCB correction, and renegotiating cost while maintaining the same electrical and mechanical parameters.
BOM optimization scope at Siltegro
Component availability audit
Verification of the status of every BOM item at major distributors: availability, lead time, identification of End of Life (EOL) or Last Time Buy (LTB) components. The result is a report flagging high-risk items.
Substitute proposals
For problematic components — a proposal of direct substitutes (identical parameters, same footprint) or substitutes requiring a minor PCB correction. Every proposal with technical justification.
Material cost reduction
Comparison of current component prices with available equivalents of equal parameters. Consolidation of similar values (e.g. resistors) into fewer unique items — fewer part numbers, better price with larger order volumes.
Design compliance verification
Every proposed change is checked for electrical, mechanical and thermal compliance with the original design — optimization does not change device functionality.
Documentation update
The optimized BOM is delivered in a production-ready format — with a full specification of substitutes and justification of every change.
When does BOM optimization deliver the most value?
Projects with End of Life components
If any component in the BOM has an EOL or Last Time Buy status, production is at risk of stopping at any moment. Optimization identifies and eliminates this risk before it becomes a problem.
Projects transferred from another EMS supplier
A production transfer is a natural moment for a BOM review — documentation from the previous supplier may contain outdated part numbers or components unavailable for months.
Products scaling from prototype to series
A BOM optimized for single-unit prototype availability may not work for volume orders — different pricing and logistics requirements at a larger scale.
Projects under cost pressure
When the product margin is tight, reducing material cost by a few percent per component translates into a real difference in the profitability of the whole series.
What sets us apart in BOM optimization?
Optimization without changing functionality
Every proposed change keeps full electrical and mechanical compliance with the original design — cost optimization, not a redesign.
Flexible component sourcing
Access to many distributors and manufacturers lets us propose substitutes that are not obvious from a first review of the catalogues.
Optimization as part of the DFM process
The BOM is reviewed together with DFM analysis before the first prototype — component availability problems are detected before they affect the production schedule.
Service scope
| Availability audit | Status at major distributors, EOL/LTB |
| Substitute proposals | Direct or requiring a PCB correction |
| Compliance verification | Electrical, mechanical, thermal |
| Report | List of changes with technical justification |
| Output format | Production-ready BOM |
| Contact time | 24 hours |
What to prepare for a BOM optimization request?
BOM file
In Excel or CSV format, with manufacturer part numbers
Schematic
If available, it helps verify substitute compliance
Optimization goal
Cost reduction, EOL elimination, scaling preparation or a combination
Production volume
Helps assess the viability of specific substitutes at the target scale