Design changes affect multiple systems
In home appliances, small design changes often impact more than one system. Increasing drum size or motor RPM in a washing machine can change the control PCB, bracket layout, drive belt, and even vibration isolation. These dependencies are rarely captured in standard costing models. Excel sheets only adjust part prices, without re-evaluating process flow or cycle time. ASI Engineering traces these impacts by re-modelling each part with updated specs, then re-costing inside xcPEP using real manufacturing steps, volumes, and rates.
Bought-out parts have no internal visibility
Compressors, motor modules, and PCB assemblies are usually procured as complete units. Most tools treat them as single-line items, with no insight into what drives the cost. Cost consultants apply top-down estimates, and benchmarks rely on external averages. ASI Engineering tears down these assemblies, identifies internal components, maps manufacturing operations, and builds a structured cost model in xcPEP. This gives sourcing teams a part-wise view of how the system is built and where cost comes from.
Tooling defines part cost in plastics and foaming
Tubs, trays, and structural enclosures are produced using tooling-intensive methods like injection moulding or thermoforming. Their cost depends on tool design, cycle time, cooling rate, and number of cavities — not just material. Traditional tools apply per-kg costing or ignore tool amortisation entirely. ASI Engineering models the tooling layout and maps actual process time based on geometry and resin type. These parameters are built into each xcPEP model and update automatically across variants.
Mechanical and electrical systems are costed in isolation
A change in motor performance may affect the PCB, sensor wiring, frame design, and assembly test time. In most costing tools, these are treated as separate components with no cost linkage. This disconnects leads to inaccurate targets and missed trade-offs. ASI Engineering connects all relevant subassemblies inside xcPEP. When a spec changes, the model updates connected steps like motor winding, PCB placement, or bracket welding, ensuring the full impact is visible.
No reference cost for local sourcing decisions
When switching to a local supplier for motors, harnesses, or compressors, teams often have no baseline for what the part should cost. Most estimates use region-wide averages or historical quotes, which miss supplier-level differences in process and scale. ASI Engineering builds first-principles cost models using real production logic, applies region-specific inputs from xcPROC, and delivers the output in xcPEP. This gives internal teams a grounded reference when validating or negotiating supplier quotes.
Comprehensive, Part-Level Costing for Home Appliances
Cycle times, scrap rates, machine loads, and regional labour costs are sourced from xcPROC and applied in xcPEP, resulting in a complete and transparent cost model that mirrors real production. This gives sourcing and design teams the clarity to set targets, validate quotes, and drive informed cost-reduction initiatives.
In depth Costing of Wiring Harnesses and Connectors
In depth Costing of Plastic and Sheet Metal Parts
In Depth Costing of PCBs and Electronic Boards
ASI Engineering performs detailed cost modelling for inverter boards, control PCBs, display units, and other electronic assemblies. Each board is analysed for layer count, component density, soldering type, and testing method. Real data from xcPROC is used to calculate machine time, labour, and material cost, giving an accurate cost structure for each board
Accurate Inputs for Cost Modelling
ASI Engineering uses a comprehensive set of verified inputs when building part-level cost models for home appliances. This includes machine hour rates, labour hour rates, raw material prices, currency conversion, and detailed process operations—all tailored to the specific region and manufacturing method. All input data is sourced from xcPROC, ensuring that each cost estimate reflects actual factory conditions, material costs, and production logic with no generic assumptions.
Scenario Costing for Design and Supplier Changes
ASI Engineering uses xcPEP to simulate the cost impact of design changes, alternate materials, or new sourcing decisions. Multiple scenarios can be created, saved, and compared to support clear decision-making.
Plastic Moulding
Injection Moulding
- Hot Runner Moulding
- Cold Runner Moulding
- Multi-Cavity Moulding
- 2K / Dual Shot Moulding
Insert & Overmoulding
- Insert Moulding
- Vertical Insert Moulding
- Soft Overmoulding
- Multi-Material Overmoulding
Gas-Assisted Moulding
- Internal Gas Injection
- Short Shot Moulding
- Hollow Section Moulding
Other Moulding Processes
- Blow Moulding
- Rotational Moulding
- Thermoforming
- Vacuum Forming
Welding & Joining
Spot & Resistance Welding
- Spot Welding
- Projection Welding
- Seam Welding
- Cross Wire Welding
Arc & MIG Welding
- Manual Arc Welding
- MIG Welding
- TIG Welding
- Continuous Seam Welding
Ultrasonic & Plastic Welding
- Ultrasonic Spot Welding
- Ultrasonic Line Welding
- Vibration Welding
- Hot Plate Welding
Joining Techniques
- Riveting
- Clinching
- Adhesive Bonding
- Screw Fastening
Surface Finishing
Painting & Coating
- Powder Coating
- Electrostatic Spray Painting
- Epoxy Coating
- Liquid Enamel Coating
Pre-Treatment
- Degreasing
- Phosphating
- Passivation
- Water Rinsing
Metal Plating
- Nickel Plating
- Chrome Plating
- Zinc Plating
- Electroplating
Surface Finishing
- Buffing
- Polishing
- Sanding
- Shot Blasting
Thermal Insulation & Foaming html Copy Edit
PU Foaming
- Low-Pressure PU Foaming
- High-Pressure PU Foaming
- In-Cavity Foaming
- Foam Density Control
Insulation Panel Assembly
- Vacuum Insulated Panels
- EPS Sheet Fitting
- PU Slab Placement
- Reflective Film Lamination
Foam Mold Fixtures
- Cabinet Moulds
- Door Foaming Moulds
- Rotating Fixtures
- Heated Steel Plates
Foaming Process Aids
- PU Mixing Heads
- Flushing & Purging Systems
- Cycle Time Control
- Foam Overflow Traps
Final Assembly & Packaging
Mechanical Assembly
- Snap Fit Assembly
- Screw Fastening
- Riveting
- Clip Mounting
Electrical Assembly
- Connector Crimping
- Wire Routing
- Terminal Fixing
- Harness Mounting
Packaging & Kitting
- Carton Assembly
- Thermocol / Foam Inserts
- Accessory Pouch Insertion
- Instruction Leaflet Insertion
Testing & Labeling
- Leak Testing
- Electrical Function Test
- Barcode & Serial Tagging
- Final Quality Stamp
AI-Based Component Identification for PCBs
In home appliances, PCBs are used across inverter boards, control modules, displays, and power supply units. Identifying each component manually is slow and error-prone, especially when dealing with large teardown batches.
ASI Engineering uses an AI-based imaging setup to scan each PCB and automatically identify mounted components such as ICs, capacitors, resistors, and connectors. The data is matched against xcPROC to populate fields like part name, value, and manufacturer. The BoM is then displayed inside xcPEP for review and costing.
Bounding Box Dimension Capture for Large Parts
Dimensional inputs like length, width, and height are essential for costing plastic, sheet metal, and structural parts in appliances. Manual measurement using calipers or tapes is often slow and inconsistent, especially for irregular or bulky parts.
ASI Engineering uses a laser-based system to measure all three dimensions without physical contact. The part is placed inside a calibrated enclosure, and the bounding box values are recorded and transferred into xcPEP for use in process and packaging cost calculations.
Projected Area Capture System
Projected area is a key input for calculating tonnage in moulding and sheet forming. It also affects material usage and surface finishing in panels, trays, and structural covers.
ASI Engineering uses a calibrated vision system to scan the part, detect the outer profile, and calculate the 2D area in real units. This is especially useful for high-volume costing of repeat parts like washing machine covers, microwave panels, or refrigerator liners.
Transparent Cost Visibility
ASI Engineering provides part-wise cost breakdowns built from real manufacturing steps, not averages or estimates. Every material, process, and operation is traceable—giving teams full visibility into how cost is created across plastics, metals, and electronics.
Faster Alignment Across Teams
With structured costing in xcPEP, sourcing, engineering, and finance teams work from the same set of data. This reduces back-and-forth during reviews and helps cross-functional teams converge on cost targets more quickly.
Baseline for Cost Reduction and Localisation
Structured costing provides a clean reference for identifying high-cost parts, comparing alternative builds, or evaluating regional production strategies. This supports ongoing cost-down initiatives without compromising function or quality.
Stronger Supplier Negotiations
With part-wise costing and process-level transparency, commercial teams can enter supplier discussions with confidence. The data acts as a neutral baseline to support renegotiations, clarify expectations, and reduce pricing ambiguity.
Make-vs-Buy Decisions
Structured cost data enables internal teams to evaluate whether a component should be sourced externally or produced in-house. With process-level granularity, teams can model both options and compare them directly.
Column Title
SpreadSheets
BOM based tools
Management Consultants
xcPEP + ASI Engineering
Real-world process accuracy
Verified input data
High-speed performance
Shorter learning curve
Comprehensive process coverage
Scalable engineering support
Lower cost of ownership
API-based integration
In-House Cost Lab Setup
xcPEP was deployed to establish a cost lab for a global washing machine manufacturer, following a Build–Operate–Transfer model. ASI Engineering configured the platform, migrated legacy costing data, and aligned xcPEP with the customer’s BOM structure and appliance hierarchy. Joint costing projects were executed to build initial models and train the internal team. Once confident, the team fully took over operations. Today, they run their own cost lab on xcPEP, with ASI providing database updates and support as needed.
Should Costing for New Part Development
xcPEP was deployed for a global kitchen appliance manufacturer to support should costing during early part development. ASI Engineering worked with the design and sourcing teams to cost key components such as motor housings, heating coils, and PCB assemblies before supplier quotes were received.
Cost estimates were built using real manufacturing steps and xcPROC inputs for region specific machine, labour, and material rates. This helped define cost targets early and reduced dependency on external benchmarks during sourcing.
Fact Packs for Supplier Negotiations
xcPEP was deployed for an air conditioner manufacturer to support cost-backed supplier negotiations. ASI Engineering created detailed cost references for components such as brackets, control panels, harnesses, and display systems. Each part was modelled based on real manufacturing operations like injection moulding, spot welding, and SMT assembly.
The outputs were compiled into structured negotiation packs, helping teams validate supplier quotes, identify cost gaps, and negotiate from a clear position of process-level understanding.
Competitor Cost Benchmarking
xcPEP was used to benchmark the cost of a client’s refrigerator against a competing brand. ASI Engineering conducted a structured teardown of both models, capturing detailed inputs on materials, assembly methods, and component choices. Each part was modelled using real manufacturing logic and costed using region-specific data from xcPROC.
The outcome was a side-by-side cost comparison at the part and system level, helping the client identify cost gaps, design inefficiencies, and opportunities for sourcing or value engineering improvement.
