Engineering Resource Bottlenecks and Scaling Limitations

$30K-$150K per project in rework from config errors and proportional engineer hiring costs. • $50K-$200K per delayed project in engineering overtime and lost revenue from extended lead times. • Dependence on engineering for every serious incident review adds hundreds of engineering hours per year, equivalent to $200k–$600k in avoidable cost, while slow or inconsistent safety responses expose the OEM to high-severity risks such as fines, legal settlements, or forced retrofits easily reaching $1M+ over a few years.

Copying historic order configs manually in spreadsheets and WhatsApp coordination for quick adaptations. • Manual tracking of custom designs, adaptations, and compliance validations using spreadsheets and email threads. • Safety officers pull together drawings, method statements, and design changes from project folders, then chase engineers and project managers for clarifications. They track incidents, site-specific configurations, and follow-up actions in Excel, email, and manually updated registers.