Areas of waste reduction Percentage of design waste Designs never used, completed, or delivered Unknown Downtime from hunting for information and waiting for test results
Unnecessary documents and prototypes 33 to 50% Underuse of design knowledge that leads to costly parts
Overdesign such as features customers don't need
Identifying manufacturing errors late in the design process
Designs that lead to defects

18% —
8% —
17% —
15% —

The figures come from an analysis of automotive Tier 1 suppliers and the A.T. Kerney study The Line on Design, 2003.