In product development, especially for industrial equipment, access hardware (like latches, handles, hinges, locks, etc.) is sometimes treated as an afterthought – something to specify once the overall design is nearly finished. Engineers may focus on the “big” components like frames, circuitry, engines, etc., and leave the selection of door latches or panel fasteners until late in the process.

 

This common approach of deferring hardware decisions can lead to significant risks and inefficiencies. As many manufacturers have learned, late-stage changes or compromises on hardware can cause design headaches, delays, and added costs that far outweigh any perceived convenience of waiting.

 

Conversely, prioritizing hardware early – integrating those choices into the initial design – brings substantial benefits: smoother manufacturing, fewer surprises, and a better end product.

 

The Pitfalls of Late-Stage Hardware Specification

Waiting until the last minute to choose or integrate hardware can create several problems. Here are the key risks if hardware is not prioritized early:

 

Design Compromises:

When hardware is chosen late, the team may have to “make it work” with an off-the-shelf component that isn’t ideal, leading to compromises in design. One enclosure manufacturer observed that many clients who put off enclosure/hardware design end up “attempting to make [standard off-the-shelf items] work for their product,” which often means concessions or compromises that require additional work.

 

In practice, this could mean a latch that doesn’t perfectly fit the space, so the engineers must cut an awkward hole or add shims, or a handle that isn’t the preferred style, but gets used because it’s the only one that fits the pre-made panel cutout. 

 

Delaying hardware design frequently results in “opting for what is available over what is best”, as one design firm put it (systium.com). The product may thus suffer in usability or aesthetics because the ideal hardware wasn’t planned from the start. In a work truck context, for example, a team might design a storage compartment and later realize they need a latch that fits a heavy winter glove; if the available latch is smaller than anticipated, they might have to accept a latch that isn’t fully usable or harder to operate (a compromise that could have been avoided with earlier planning).

 

Engineering Rework & Iterations 

Late hardware integration can force redesigns of parts and assemblies, causing rework late in the project or more costly custom parts. If a chosen latch doesn’t fit the allocated space on a door, the door design must be modified; if the hinge can’t support the load, the mounting points might need reinforcement. Such changes in late stages are time-consuming and costly.

 

It’s well known in engineering that the later a change is made, the more expensive it becomes. Early in development, changes are cheap (just a design tweak), but after drawings are done or tooling is made, changes mean scrap and redo. Industry experts note that “the cost of each change increases [with time] because more time, money, and energy have been invested”  by that point.

 

In product development, a commonly cited rule is that by the time you are in detailed design or prototyping, a huge portion of the product’s cost and constraints are already locked in. One study found - 85% of a project’s life-cycle cost is committed by the end of the system design phase, meaning if you wait until later to decide on hardware, you might discover a needed change after 85% of costs are fixed, making modifications extremely costly. 

 

Late hardware decisions can therefore trigger “expensive engineering change orders” to fix interference issues, structural problems, or compliance failures that would have been caught with earlier consideration.

 

Delays in Time-to-Market

Redesigns and hunting for last-minute hardware can also delay the project schedule. If the required latch or handle has a long lead time or is out of stock (something the procurement team discovers late because the BOM wasn’t finalized), production might be held up.

 

Additionally, unexpected testing failures related to hardware can appear – for instance, if a prototype fails an environmental test because a seal on a door wasn’t adequate, you face a scramble to find a better latch or gasket and then re-test. All this pushes out launch dates. A hardware development blog pointed out that once development is underway, late changes “drift the schedule” significantly.

 

In complex products, design changes from testing failures (often due to issues that would have been caught by earlier integration) require going back to the drawing board, “which takes significant time” . For industries like automotive or heavy equipment, a delayed product can mean missed market windows or contractual penalties for late delivery. In short, procrastinating on hardware decisions often translates to project delays when inevitable adjustments crop up.

 

Manufacturing and Assembly Issues

Another risk is that by not considering hardware early, the product may be difficult or inefficient to assemble. Hardware contributes to Design for Manufacturability (DFM) – things like hole placements, weld-nuts for mounting, space for tools to tighten bolts, etc.

 

If these considerations come in late, the design might already have suboptimal geometry that makes assembly tricky. This can lead to last-minute “band-aid” fixes on the factory floor (like drilling extra holes or using custom brackets) that increase labor time and cost.

 

A proactive approach would be to involve hardware in the CAD model from the beginning so that the enclosure or frame is designed for easy integration of that hardware (proper clearances, mounting features, etc.). Late involvement means those optimizations are missed, and the build might require more steps or special accommodations.

 

In summary, treating access hardware as an afterthought can result in a domino effect of compromises, rework, delays, and inefficiencies that hurt both the product and the bottom line. Many of these headaches are preventable by simply pulling hardware considerations forward in the design timeline.

 

Benefits of Early Hardware Integration (DFM and BOM Alignment)

Prioritizing and specifying hardware early in the design cycle brings several clear advantages, turning the pitfalls described above into opportunities:

 

Optimal Design & Fit 

When hardware is considered from the outset, the product design can be tailored for the ideal components rather than forcing a fit later. This means no compromises on functionality or quality. For example, if you know you need a robust compression latch on an HVAC access panel, you can design the panel size, thickness, and reinforcement around that latch’s requirements (ensuring a perfect fit and seal).

 

Early enclosure planning “in the early stages of development ensures your enclosure fits your product well, is made of the right materials, has a long life, and meets all requirements”.  In other words, everything works together seamlessly. Clients who take this approach can choose the best hardware for the job (be it for ergonomics, strength, or longevity) and then design around it, rather than selecting whatever fits a frozen design.

 

This results in a superior end product – for instance, a work truck designed with input from a hardware supplier might incorporate purpose-built latches that are easy for users to operate with gloved hands and that align perfectly with the truck’s locking system.

 

The user experience and product integrity are improved by those early choices.

 

1. Design for Manufacturing (DFM): 

Early hardware selection allows the engineering team to incorporate DFM principles related to that hardware. They can ensure from the beginning that the mounting and assembly of the hardware are efficient. For instance, if a certain hinge will be used on a cabinet, the sheet metal can be designed with the correct hole pattern or PEM fasteners in place initially, so that assembly is just a bolt-on process. This kind of foresight eliminates the need for awkward retrofits.

 

As one source notes, considering all aspects of a product’s design at once – including the enclosure and hardware – results in a much better fit and more efficiently produced end product. Additionally, involving hardware experts early can surface manufacturing suggestions: perhaps a different latch could reduce welding by using clips instead of studs, or a different handle could simplify wiring for door alarms. These choices can greatly streamline production. In short, early integration means fewer assembly steps, fewer special workarounds, and often lower unit cost due to design simplification.

 

 

 

 

2. Complete BOM and Early Procurement: 

Finalizing hardware choices early means the bill of materials (BOM) for the product will be more complete, earlier. This has a huge benefit for the supply chain: procurement can start sourcing critical hardware components well ahead of production. According to an electronics sourcing guide, “A complete Bill of Material allows procurement to source parts early. Early sourcing of components drives competitive pricing for the enterprise."  This point applies to mechanical hardware too – if you know by design freeze exactly which latch, gas spring, and lock you need, your purchasing team can negotiate better prices and secure stock in advance. It reduces the risk of late-stage part shortages.

 

By contrast, a partial BOM that’s missing hardware until late keeps procurement in the dark, which can lead to last-minute scrambling or paying a premium for fast delivery. Early BOM alignment also means no unpleasant surprises: you won’t find out in the 11th hour that the perfect handle is backordered for 8 weeks, because you would have locked it in and ordered it long before. One technical article described how having real-world parts identified early prevents “endless feedback loops after procurement finds items difficult to source or the cost exorbitant” – essentially, it avoids the scenario where procurement comes back and says “this latch is unavailable or too expensive, find an alternative,” which then forces design changes. Thus, early hardware decisions keep the supply chain synchronized with design, enabling on-time production starts and cost control.

 

Fewer Late Changes and Faster Testing

Incorporating hardware early means that prototypes and test units will have the final (or close to final) hardware on them. This allows you to test the product under real conditions (vibration, temperature, user handling) with the actual latches/handles that will be used.

 

Issues can be identified and resolved when changes are still relatively easy. If the product passes all its validation tests with hardware integrated from the start, you have confidence going into production. You avoid the situation of discovering a hardware-related flaw at the validation stage (which is late), because you’ve been validating with the correct hardware all along. This, in turn, accelerates time-to-market. In essence, front-loading the design process with all components leads to smoother and quicker development cycles.

 

As one manufacturing quality report put it, when suppliers (or components) are involved early, it “makes the project more feasible to manufacture,” and avoids the cost and time of later fixes pmiquality.com.

 

Holistic Optimization (System Performance)

 With hardware in mind from the beginning, the design team can also optimize the system-level performance better. For instance, in an electrical cabinet design, knowing the hinge and latch selection early lets you calculate how often it can be opened or how it holds up to certain loads, influencing the design of the cabinet structure accordingly. Or in a vehicle door, selecting the latch mechanism early allows you to design the door frame, sealing, and even the mating striker on the body for perfect alignment and force distribution.

This avoids band-aid fixes like adding shims or foam later to improve fit. It can also reduce weight or complexity by eliminating over-engineering “just in case” hardware doesn’t fit – when you know exactly what’s being used, you can confidently trim material elsewhere. All told, early hardware integration means fewer unknowns in design, allowing engineers to optimize everything with full information.

 

Real-World Examples

Work Truck Example: Consider a company designing a new service body for a work truck (those utility trucks with multiple tool compartments on the sides). These compartments need heavy-duty door latches, locks, and hinges that can endure daily use, vibration from driving, and weather exposure. If the truck body engineers involve an access hardware specialist like Allegis at the concept stage, they might decide on, say, a specific three-point locking system for each compartment door early on.

 

This early decision will influence the door frame design (to accommodate the latch rods and cam), the reinforcement of the sheet metal where the handle mounts, and the selection of a gasket to ensure a weather-tight seal when the latch is closed. The result is a set of compartments that are secure, easy to use, and sealed from water – all accomplished with minimal rework because the hardware was part of the initial design criteria. 

 

If done late, however, the engineers might have built the compartments and then realized standard locks don’t fit the space or meet the strength required – at that point, fixing it could mean cutting into finished panels or settling for a less secure single-point latch.

 

Early planning yields a superior, more durable truck body with less effort. In practice, many truck body manufacturers now collaborate with hardware providers early for this reason, ensuring things like door ajar sensors, padlock provisions, and ergonomics are baked in from the start rather than bolted on after the fact.

 

HVAC Equipment Example: Large commercial HVAC units often sit on rooftops or outdoors. They have access panels for filters, fans, and controls. If hardware selection is delayed, designers might finalize the sheet metal layout only to later cut holes for whatever latch they find, possibly compromising the panel’s rigidity or the seal.

 

But if they prioritize hardware, they could choose, for example, a flush compression latch that is UL-certified and rated for outdoor use at the outset. They would then design each access door panel to fit that latch’s installation requirements, and ensure there’s a proper lip for a gasket to meet the latch cam, etc.

 

This proactive approach guarantees that when the unit is built, each panel closes tightly and meets the required NEMA or IP rating for the HVAC enclosure without additional tinkering. It also means maintenance personnel will have properly designed handles to open panels safely. Additionally, early hardware choice can help in compliance – many HVAC units must meet UL standards (like UL 1995 or UL 60335), which include requirements for access panels.

 

By selecting UL-listed hardware from the start, the manufacturer streamlines certification. In contrast, a late change because a panel kept leaking in rain (due to a subpar latch) could force an expensive redesign or field retrofit of hundreds of units. So in HVAC, early hardware integration is key to meeting performance, safety, and regulatory requirements on schedule.

 

Electrical Switchgear Example: Switchgear and electrical enclosures (like those housing circuit breakers or transformers) demand high reliability for safety. They often have intricate hardware: multi-point latching systems to ensure door alignment, interlocks that prevent opening under load, padlock provisions for lockout-tagout, etc. If an enclosure is designed without confirming the hardware early, there’s a risk that once you add the latching mechanism, something won’t line up or the door won’t meet the required UL/NEMA rating.

 

For instance, UL 50 (standard for electrical enclosures) and associated NEMA standards specify tests for rain, dust, etc. Using a tested latching system greatly aids in passing these tests. A company that prioritizes the latch and hinge selection early will design the enclosure around those components, making sure the enclosure stiffeners align with latch strikers, providing mounting points for hinges that bear the door’s weight, and considering the cable routing such that nothing interferes with the hardware operation.

 

Early involvement might also surface a need for custom solutions (for example, a secondary lock or a specific handle shape for an operator with a gloved hand), which can be developed in time for production. If done late, you might realize during prototype testing that the door flexes too much to maintain a seal and needs an extra latch – then you’d have to scramble to add one, cutting new holes and perhaps failing initial certification rounds.

 

By engaging hardware experts early, switchgear designers can ensure safety features and robust access mechanisms are built-in from the beginning, avoiding costly redesigns and ensuring end-user safety and convenience.

 

These scenarios underscore a common theme: the earlier the hardware is locked in, the smoother the design and implementation process for products that rely on that hardware. In each case, early consideration prevented problems and added value:

 

      • The work truck had better functionality and no rework.
      • The HVAC unit met its ingress protection targets without delay.
      • The switchgear satisfied safety standards efficiently.

 

Partnering Early with a Systems-Level Hardware Expert

One of the best ways to prioritize hardware early is to involve a trusted hardware supplier or expert in the early design phase. Allegis Corporation, for example, aims to be a systems-level partner rather than just a component vendor. This means they collaborate with customers’ engineering teams during the design cycle to help select the right access hardware and ensure the product is designed to accommodate it optimally.

 

By doing so, they help customers avoid the pitfalls of late changes and achieve the benefits described above. An Allegis engineer might assist in reviewing a 3D model of a machine enclosure when it’s still in CAD, suggesting reinforcements around a hinge or recommending a different latch if they foresee an alignment issue – long before anything is built. This kind of partnership embodies the idea that “access matters” at the beginning of design, not the end.

 

Early supplier involvement has been shown to reduce costs and development time by leveraging the supplier’s specialized knowledge (they know their hardware’s nuances best). It can also spur innovation: perhaps a new latch mechanism could simplify an entire assembly, but the design team wouldn’t know about it if they hadn’t talked to the hardware supplier early on.

 

By prioritizing hardware in the design cycle and treating suppliers as design partners, companies can unlock these advantages.

 

In conclusion, prioritizing access hardware earlier in design is a smart strategy that de-risks projects and leads to better products. It mitigates late-stage surprises that cause compromise, rework, or delay. It aligns the BOM and procurement so that manufacturing can proceed without hiccups. And it enables a more holistic, optimized design where the hardware truly complements the system rather than the other way around. 

 

Successful modern product development treats hardware as integral from day one. By doing so – and by partnering with companies like Allegis, who support system-level design – manufacturers in industries from work trucks to HVAC to electrical equipment can ensure their access hardware not only meets functional needs but also adds strategic value (in reliability, cost, and user satisfaction) to the end product. In the race to innovate without sacrificing quality, paying attention to the little things (like latches and hinges) early on can make a big difference. Access matters, and it matters sooner than you think.