Passive Component Consolidation
Optimize your Bill of Materials by consolidating similar passive components into fewer part numbers, reducing procurement complexity and manufacturing costs.
Overview
The Passive Component Consolidation feature uses AI to analyze your Bill of Materials (BOM) and identify opportunities to simplify passive component selection. By finding components with similar values that can be replaced with a single Manufacturer Part Number (MPN), you can reduce costs through volume discounts, simplify procurement, and streamline manufacturing—all while maintaining circuit functionality.
This feature is particularly valuable during the design-for-manufacturing phase, where optimizing the BOM can lead to significant cost savings in production.
What It Does
Copilot analyzes passive components in your design (resistors, capacitors, and inductors) to find:
- Components with marginally close values that could use the same part
- Groups of components within ±50% value tolerance with the same package code
- Single MPN replacements that can satisfy multiple component requirements
- Cost reduction opportunities through component standardization
How to Access
You can access Passive Component Consolidation through the context menu:
- Right-click anywhere on your schematic canvas
- Navigate to Copilot → Passive Components Consolidation
- Copilot will analyze your BOM and provide recommendations
The feature is located in the "Manufacture" section of the Copilot menu, alongside other production-readiness tools like FMEA generation and test plan creation.
How Copilot Analyzes Your BOM
When you run Passive Component Consolidation, Copilot performs a comprehensive 6-step analysis:
1. Component Identification
Copilot extracts all passive components from your design, capturing:
- Designator (e.g., R1, C3, L5)
- Component value (e.g., 10kΩ, 0.1µF, 100nH)
- Package code (e.g., 0603, 0805, 1206)
- Current Manufacturer Part Number (MPN)
2. Value and Package Grouping
Components are grouped based on:
- Value tolerance: Components within ±50% of each other
- Package compatibility: Same package code to ensure footprint compatibility
- Component type: Resistors, capacitors, and inductors are analyzed separately
3. MPN Analysis
For each group, Copilot:
- Checks if all components use the same MPN
- Identifies groups with multiple different MPNs
- Evaluates part availability and specifications
4. Single MPN Recommendations
Copilot cross-references specifications to find a single MPN that can:
- Replace all components in a group
- Meet or exceed all electrical requirements
- Maintain the same package size
- Provide better availability or cost advantages
5. Comparison Table Generation
Results are presented in a clear comparison table showing:
- Original component designators and values
- Current MPNs being used
- Recommended consolidated MPN
- Specification comparison
- Estimated cost impact
6. Implementation Guidance
Copilot provides:
- Clear recommendations for which components to consolidate
- Justification for each suggested change
- Considerations for voltage ratings and other critical specifications
- Expected benefits from each consolidation
Example Use Cases
Example 1: Multiple Resistor Manufacturers
Before consolidation:
- R1, R2, R3: 10kΩ ±1%, 0603 → Each from different manufacturers
- Three different MPNs in BOM
- Small quantity orders for each MPN
After consolidation:
- R1, R2, R3: 10kΩ ±1%, 0603 → Single manufacturer (e.g., Yageo RC0603FR-0710KL)
- One MPN in BOM
- Volume pricing on larger quantity
Result: 15-25% cost reduction through volume discounts
Example 2: Similar Capacitor Values
Before consolidation:
- C1: 0.1µF, 0805, 50V
- C2: 0.12µF, 0805, 50V
- C3: 0.15µF, 0805, 50V
- Three different MPNs
After consolidation:
- C1, C2, C3: 0.1µF, 0805, 50V → Single MPN
- Design validated that 0.1µF works for all three locations
Result: Simplified BOM, reduced inventory, maintained circuit performance
Example 3: Pull-up Resistor Standardization
Before consolidation:
- R10: 4.7kΩ, 0603
- R11: 5.1kΩ, 0603
- R12: 4.3kΩ, 0603
After consolidation:
- R10, R11, R12: 4.7kΩ, 0603 → Single MPN
- All values within acceptable tolerance for pull-up application
Result: Three line items reduced to one
Benefits
Cost Reduction
- Volume discounts: Larger quantities of fewer parts qualify for better pricing
- Reduced inventory: Less variety means lower carrying costs
- Simplified procurement: Fewer purchase orders and vendor relationships
Manufacturing Efficiency
- Fewer pick-and-place stops: Reduced component variety speeds up assembly
- Lower setup costs: Fewer unique parts means less machine configuration time
- Reduced error risk: Simpler BOM reduces assembly mistakes
Supply Chain Advantages
- Better availability: Standardizing on common parts improves stock availability
- Easier sourcing: Fewer unique parts to source during component shortages
- Simplified inventory management: Less warehouse space and tracking overhead
Design Flexibility
- Maintained functionality: All consolidations preserve circuit performance
- Future design reuse: Standardized component library across projects
- Faster future designs: Pre-approved component list for common values
Tips for Effective Use
When to Run Consolidation
- After initial component selection: Once you've selected components that meet specifications
- Before finalizing design: During design-for-manufacturing review
- When optimizing costs: As part of value engineering efforts
- Before production: One final check before committing to manufacturing
Review Recommendations Carefully
- Verify voltage ratings: Ensure consolidated parts meet or exceed voltage requirements
- Check temperature coefficients: Important for precision circuits
- Consider tolerance: Verify ±1% vs ±5% doesn't affect performance
- Validate power ratings: Especially critical for resistors
Best Practices
- Start with obvious groups: Begin with clear consolidation opportunities like pull-up resistors
- Consider availability: Check that recommended parts are readily available
- Think long-term: Choose parts that will be available for product lifetime
- Document decisions: Keep notes on why certain consolidations were accepted or rejected
- Test after changes: Validate circuit performance after any modifications
Communication with Team
- Share recommendations: Discuss consolidation opportunities with your team
- Get approval: Ensure changes are reviewed before implementation
- Update documentation: Reflect consolidation decisions in design notes
- Consider manufacturing input: Consult with assembly team on part preferences
Limitations
Component Scope
- Passive components only: Currently analyzes resistors, capacitors, and inductors
- MPN required: Components must have Manufacturer Part Numbers assigned
- Standard packages: Works best with common package sizes (0402, 0603, 0805, etc.)
Specification Verification
- Voltage ratings: You must verify voltage ratings meet requirements
- Temperature coefficients: Important specs must be manually validated
- Power ratings: Critical parameters require engineer review
- Specialized components: High-precision or specialized parts may not be suitable for consolidation
Design Considerations
- Critical circuits: Precision or safety-critical circuits may need specific parts
- EMI/EMC requirements: Consolidation shouldn't compromise electromagnetic compatibility
- Thermal management: Ensure consolidated parts handle thermal requirements
- Mechanical constraints: Verify physical dimensions work in all locations
User Approval Required
- Not automatic: All changes require your explicit approval
- Engineering judgment: You must validate technical suitability
- Performance validation: Testing recommended after consolidation
- Documentation updates: You're responsible for updating design documentation
Related Features
Enhance your manufacturing workflow with these complementary features:
- Copilot - Learn about all AI-powered design assistance capabilities
- AI Testing & Debugging - Generate FMEA reports and test plans for manufacturing readiness
- AI Design Reviews - Validate design decisions before production
- BOM Export - Export optimized BOM for manufacturing
- Getting Started with Copilot - Master Copilot fundamentals
Frequently Asked Questions
Can I consolidate active components?
Currently, Passive Component Consolidation focuses exclusively on resistors, capacitors, and inductors. Active components like ICs, transistors, and diodes have more complex specifications that require individual selection.
Will consolidation affect circuit performance?
Copilot only suggests consolidations within ±50% value tolerance and same package size. However, you should always verify that suggested changes maintain circuit functionality, especially for precision or timing-critical circuits.
How do I accept or reject recommendations?
Copilot presents recommendations in the chat interface. You can review each suggestion and choose to accept or decline. Changes are only made to your design with your explicit approval.
Can I undo consolidation changes?
Yes, all Copilot actions can be undone using the standard undo functionality (Ctrl+Z) or through your project's version history.
Does this work with custom components?
The feature works best when components have MPNs assigned. For custom components or those without MPNs, consolidation recommendations may be limited.
How much cost savings can I expect?
Savings vary based on your design, but typical consolidation efforts can reduce BOM costs by 10-30% through volume discounts and simplified procurement. The largest savings come from designs with many similar passive components.
Next Steps
Now that you understand Passive Component Consolidation, explore these related topics:
- Learn how to generate comprehensive test plans for your design
- Discover AI-powered design reviews to catch issues early
- Master Copilot's other tools for faster PCB design
- Explore BOM optimization strategies for cost-effective manufacturing