EV Market Growing Pains

How To Prepare For Rapid Growth

by Mehrdad Safaieh, Business Leader, CA

As the Electric Vehicle (EV) market experiences unprecedented growth, it faces significant challenges that can hinder progress. This article by Mehrdad Safaieh delves into the complexities of rapid market expansion, emphasizing the critical role of effective release and change management in overcoming engineering delays, integrating multiple systems, and ensuring efficient data handling. Highlighting a dual approach of consulting and doing, it showcases how our team's hands-on involvement in managing complex processes and data has led to measurable success in EV startups. By tackling both theoretical and practical aspects, the article provides valuable insights and strategies to help EV companies navigate through the intricacies of growth, innovation, and market entry, offering a roadmap for startups to not only survive but thrive in the competitive EV landscape.

Published 29 May 2024

5 min read. Share via:

The Electric Vehicle (EV) market is booming with almost 20% of all cars sold last year being electric. However, with the rapid pace of growth and development, there are several challenges that need to be addressed. One of the major bottlenecks is the delay in bringing complex engineering programs to the market, with startups facing even greater delays. This highlights the need for accurate data to facilitate effective release and change management.

The Challenges of Rapid Growth

Electric Vehicle (EV) companies are known for their rapid growth, but they often face challenges in developing long-term and scalable processes. The temporary solutions they put in place initially can become entrenched and hinder efficiency and integration. One of the biggest obstacles is integrating multiple systems into a cohesive product data backbone. Without this, there is a risk of relying on offline Excel spreadsheets to manage data, which is both inefficient and prone to errors. A dedicated team is needed to implement new processes and prevent this from happening.

The Cost of Delayed Market Entry

Change Management inefficiencies can have significant consequences beyond just administrative issues. They can directly affect a company's bottom line and market position. For instance, delays in product releases not only increase costs but also put the company at risk of falling behind in a sector where technological advancements are constantly being made.

A Dual Approach: Consulting and Doing

Our team was tasked with maintaining control over an EV Startups EBOM & MBOM while cycling through rapidly changing processes. The BOM inaccuracy, poor visibility to part maturity and lack of confidence in data, were driving up costs and slowing down timelines. To overcome these challenges, we adopted a unique, hands-on approach. We didn't just design improved systems and processes but also actively participated in the implementation process. We played a dual role as consultants and doers, which helped us expedite training for engineers on the new streamlined processes while simultaneously catching up on builds. Our approach emphasized that effective change management requires more than just theoretical solutions; it demands active problem-solving and implementation.

The Solution: Expertise in Complexity

Our proficiency in managing complex configurations and data is a crucial advantage, especially in the Electric Vehicle (EV) industry. Being experts in handling data, we have devised and enhanced processes that not only tackle the immediate challenges of release and change management but also position organizations for sustainable growth. Our interventions have resulted in significant enhancements in data management, considerably reducing errors and refining the visibility and precision of Bills of Materials (BoMs).

Measurable Success in a Five-Year Program

Our approach has proved to be highly effective, as demonstrated by our work with an EV startup over five years. During this period, we were responsible for overseeing the release of approximately 100,000 parts and executing 20,000 change actions. Consequently, we improved the data quality of average attribute completeness from approximately 60% to 98% across six vehicle lines. These numbers signify more than just operational accomplishments; they indicate a significant shift in how EV startups can efficiently manage their growth and innovation pipeline. A BOM error can cost anywhere from approximately $15 if caught when authoring to well over $500 after the part is fitted into a prototype build. These error costs can quickly add up.

Lessons Learned and Best Practices

The extensive experience we gained in the EV sector has taught us some valuable lessons that can help startups succeed. Firstly, there is no one-size-fits-all solution. So, we don’t try to sell one. Instead, we focus on finding the right-sized solution based on a client’s unique business needs. We know, it's crucial to have a reliable product data management system in place as it forms the basis for scalable and streamlined processes. Secondly, it's important to have hands-on support during implementation, which requires expertise not only in planning but also in execution. Lastly, being flexible and having foresight while planning processes are crucial to navigate the fast-paced changes that are typical of the EV industry.


Effective release and change management are not just essential operations for electric vehicle (EV) startups; they are strategic imperatives. These companies face challenges in innovation, market entry, and scaling, and the lessons and strategies described here offer a roadmap to avoid common pitfalls and accelerate their path from concept to becoming a market leader.

If you are an electric vehicle (EV) startup that's on the verge of growth or struggling to scale, it is high time you evaluate and invest in your release and change management processes. By doing so, you can adopt the knowledge and systems that will not only help you bring your product to the market but also position your company at the forefront of the EV revolution. This will give you a better understanding of your current situation and enable you to make informed decisions based on accurate data.

BoM ManagementEfficiencyEngineering ManagementBoM AuditBoM & Part ValidationPrototype Build ManagementIssue ManagementRelease & Change ManagementPDM InsightsCase Study