Years of working with Automakers
First providing services using xcPEP, then deploying xcPEP as a SaaS solution.
And more vehicles torn down and costed
With more than half of them being EVs.
Automotive OEM Customers
Across India and rest of the world.
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ASI vs. Management Consultants vs. Benchmarking Companies
Approaches to Automotive Cost Engineering & Value Optimization
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| ASI – Engineering-Led Cost Transformation | Management Consultants | Benchmarking Companies |
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| End-to-end engineering-led cost transformation using xcPEP & xcPROC. Focus on sustainable, structural cost reduction across the entire product portfolio. | Strategy-driven consulting projects aimed at solving one-time problems. Engagements are billable-hour focused and often lead to recurring issues over the years. | Vehicle and component benchmarking using existing databases of 3D scans and past teardowns. Limited focus on the latest market-relevant technologies. |
| Transparent Should Costing for every part, with assumptions adapted to each company's products, supply chain, and manufacturing reality. Highly detailed, data-driven simulations for accurate cost estimation and reduction planning. | Relies heavily on subject matter experts and experience-based insights. Produces directional improvements but often lacks full product portfolio coverage. | Uses thumb-rule or formula-based costing, often less accurate than internal OEM/Tier-1 methods. Delta analysis from old models offers limited actionable insights. |
Proprietary platforms:
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General consulting toolkits, templates, and financial models. No proprietary engineering cost simulation platforms. | In-house teardown archives and CAD scans. Data mostly from outdated or obsolete vehicle models. |
| Measurable, sustainable cost reductions. Direct impact on EBITDA, sourcing efficiency, and competitiveness. | Recommendations that improve status quo but may not represent optimal or lasting solutions. | Occasional cost ideas, but low hit-rate and limited relevance to current regulatory and market demands. |
| Rapid analysis with live costing tools – weeks for entire portfolio costing. | Project timelines often span months from kickoff to final report. | Data compilation and reporting from archives – timelines vary, but insights often outdated by delivery. |
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Engineering Led Cost Transformation
Of Automotive OEMs and Tier 1 Suppliers
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| Challenge | ASI Solution | Value |
|---|---|---|
Key Challenges
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Our Framework
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Business Impact
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| Core Technology Platforms | ||
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xcPROC Procurement Intelligence
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xcPEP Costing Engine Precise Should Costing
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xcPEP Idea Module Automated Design & Commercial Idea Generation
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| Build - Operate - Transfer Engagement Model | ||
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Phase 1: Build Detailed Should-Costing Foundation
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Phase 2: Operate Idea Generation & Implementation
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Phase 3: Transfer Cost Engineering Function Handover
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| Deliverables & Outcomes | ||
Immediate
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Medium-Term
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Long-Term
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Should Cost Models for Plastic Moulded Automotive Parts in xcPEP – Should Cost Modelling Software
- Film Packaging
- Polyethylene (PE) Films
- Polypropylene (PP) Films
- Polyethylene Terephthalate (PET) Films
- Biaxially Oriented Polypropylene (BOPP)
- Cast Polypropylene (CPP)
- Biaxially Oriented Polyester (BOPET)
- Amorphous Polyester (APET)
Thermoforming
- Vacuum Forming
- Pressure Forming
- Drape Forming
- Twin-Sheet Forming
- Foam Moulding
- Structural Foam Moulding
- Architectural Foam Moulding
- Foam Crown Moulding
- Stucco Foam Trim
- EPS Shape Moulding
Extrusion Moulding – Plastic & Ceramic
- Direct (Forward) Extrusion
- Indirect (Reverse) Extrusion
- Hydrostatic Extrusion
- Blown Film Extrusion
- Sheet/Film Extrusion
- Tubing Extrusion
- Coextrusion
- Extrusion Coating
Plastic Rota Moulding
- Clamshell Machine
- Shuttle Machine
- Carousel Machine
Injection Moulding – Thermoplastic
- High-Pressure Injection
- Micro Injection Moulding
- Gas-Assisted Injection
- Thin-Wall Packaging Moulding
Injection Moulding – Thermoset
- Transfer Moulding
- Compression Moulding
- Reaction Injection Moulding (RIM)
- Blow Moulding
- Extrusion Blow Moulding
- Injection Stretch Blow Moulding
- Accumulator Head Blow Moulding
Should Cost Models for Rubber Moulded Parts
- Compression Moulding – Rubber
- Hydraulic Compression Moulding
- Transfer Compression Moulding
- Preformed Rubber Blank Moulding
- Closed Mold Curing
- Rubber Sheet Moulding
- Extrusion Moulding – Rubber
- Hot Feed Extrusion
- Cold Feed Extrusion
- Microwave Curing Extrusion
- Steam Vulcanization Extrusion
- Salt Bath Curing
- Autoclave Curing
- Injection Moulding – Rubber
- Liquid Injection Moulding (LIM)
- Vacuum Injection Moulding
- Rubber Transfer Injection
- Cold Runner Injection Moulding
- Injection Moulded Seals & Gaskets
- Extrusion Moulding – Rubber & Plastic
- Dual Extrusion (Hard-Soft Combinations)
- Co-extruded Weather Seals
- TPV and EPDM Hybrid Extrusion
- Rubber-Plastic Strip Profiles
- Edge Trim Extrusion
Should Cost Models for Metal Formed Parts
- Cold Forging
- Cold Heading
- Cold Extrusion
- Cold Impact Extrusion
- Coining
- Cold Roll Forging
Ferrous Casting – Sand Casting
- Green Sand Casting
- Resin-Bonded Sand Casting
- No-Bake Sand Casting
- Shell Moulding
- Lost-Foam Casting (Ferrous)
Hot Forging – Gear
- Upset Forging of Gear Blanks
- Cogging
- Skiving & Burnishing
- Finish Forging
Hot Forging – Crankshaft
- Preform Forging
- Rotary Forging
- Impression-Die Forging
- Finish Forging & Trimming
- Powder Metallurgy
- Cold Press & Sinter
- Hot Isostatic Pressing (HIP)
- Metal Injection Molding (MIM)
- Powder Forging
Spring – Cold Wound
- Compression Spring Coiling
- Extension Spring Coiling
- Torsion Spring Coiling
- Wire Straightening & Stress Relieving
Spring – Hot Wound
- Hot Coil Winding
- Ring Spring Forming
- Shot Peening
- Annealing
Substrate – Metallic
- Aluminum Substrate Bonding
- Copper Core Substrates
- Metal-Insulated Substrates (IMS)
- Heat-Sink Metal Cores
- Zinc Casting – HPDC
- Hot-Chamber Die Casting
- Cold-Chamber Die Casting
- Vacuum Die Casting (Zinc)
- Squeeze Casting
Zinc Casting – GDC
- Tilt-Pour Gravity Casting
- Low-Pressure GDC
- Slush Casting
- Permanent-Mould Casting
Aluminium Casting – HPDC
- Cold-Chamber HPDC
- Hot-Chamber HPDC
- Vacuum HPDC
- High-Pressure Die Casting (Al Alloys)
Aluminium Casting – GDC
- Tilt-Pour Permanent-Mould Casting
- Slush Casting
- Low-Pressure Permanent-Mould
- Semi-Solid Rheo Casting
- Brass Casting – LPDC
- Bottom-Fill LPDC
- Counter-Gravity LPDC
- Semi-Solid LPDC
- Hot-Chamber LPDC
Brass Casting – GDC
- Tilt-Pour Gravity Casting
- Permanent-Mould GDC
- Centrifugal Casting (Brass)
- Sand-Mould Gravity Casting
Hot Forging – Roll
- Cogging-Mill Roll Forging
- Controlled Rolling
- Ring Rolling
- Scale-Breaker Rolling
Hot Forging – Closed Die
- Impression-Die Forging
- Flashless Forging
- Flash-Type Forging
- Precision Forging
Automotive Should Cost Models for Metal Fabricated Parts
- Fabrication – Sheet Metal
- Laser Cutting
- Shearing
- Press Brake Bending
- Punching & Notching
- Roll Forming
- Deburring & Finishing
Machining – Gear
- Gear Hobbing
- Gear Shaping
- Gear Grinding
- Gear Broaching
- Gear Heat Treatment
- Fabrication – Structural & Others
- Steel Beam & Plate Welding
- Pipe & Tube Spooling
- Chassis & Frame Assembly
- Sheet Lamination
Metal Hose Assembly
- Spiral‐Wound Hose
- Braid Reinforced Hose
- Corrugated Hose
- PTFE Lined Hose
- Swaging & End Fitting
Stamping – Progressive Die
- Multi-station Strip Feeding
- Cutting, Forming & Piercing
- Progressive Coil Processing
- Stamping – Transfer Die
- Individual Blank Feeding
- High-Speed Compound Operations
- Automated Part Transfer
Stamping – Compound Die
- Simultaneous Cutting & Forming
- Deep Draw & Embossing
- High-Tonnage Presses
Cutting & Ablation
- Laser Cutting
- Plasma Cutting
- Waterjet Cutting
- Oxy-Fuel Cutting
- Welding & Joining
- MIG / MAG Welding
- TIG Welding
- Spot Welding
- Friction Stir Welding
- Laser Welding
Surface & finishing
- Grinding & Polishing
- Powder Coating
- Anodizing
- Galvanizing
Should Cost Models for Electrical Components
- Connectors
- Wire-to-Wire Connectors
- Wire-to-Board Connectors
- Board-to-Board Connectors
- Terminal Blocks
- Automotive Sealed Connectors
Electrical Cable
- Shielded Power Cable
- Coaxial Cable
- Ribbon Cable
- High Voltage Cable
- EV Battery Cables
Cell
- Cylindrical Cell
- Prismatic Cell
- Pouch Cell
- LFP / NMC / NCA Chemistries
- Cell Terminal Configurations
Display
- LCD Panel
- LED Backlit Display
- OLED Display
- Touch Panel (Capacitive / Resistive)
- TFT Module
- PCB – Aluminium
- Single Layer Aluminium PCB
- IMS (Insulated Metal Substrate)
- High Thermal Conductivity Types
- LED Application Boards
PCB – Copper
- Heavy Copper PCB
- High Frequency PCB
- Multilayer Copper Core
- RF Power PCBs
PCB – FR4
- Standard FR4 PCB
- Multilayer FR4 PCB
- Rigid-Flex FR4
- High Tg FR4
PCB – Ceramic
- Alumina Ceramic PCB
- Aluminium Nitride PCB
- Direct Bonded Copper (DBC)
- Low-Temperature Co-fired Ceramic (LTCC)
- PCB – Flexible
- Single-Sided Flex PCB
- Double-Sided Flex PCB
- Rigid-Flex PCB
- Polyimide Substrate
Bare PCB – 1 Layer
- FR4 / CEM1
- HASL Finish
- Basic Copper Thickness
Bare PCB – 2 Layer
- FR4 / Aluminium
- Via Drilling
- ENIG / OSP Finishing
Bare PCB – 4 Layer
- Signal-Ground-Signal-Ground Stackup
- Controlled Impedance
- Via-in-pad Design
- Bare PCB – 6 Layer
- Power-Ground Separation
- High-Speed Signal Routing
- Blind & Buried Vias
Bare PCB – 8 Layer
- Advanced Multilayer Stackup
- High-Density Interconnect (HDI)
- Thermal Management Layers
Stator
- Laminated Core Stator
- Hairpin Wound Stator
- Slotted vs Slotless Stator
- Die Cast Winding
Rotor
- Squirrel Cage Rotor
- Interior Permanent Magnet (IPM)
- Surface PM Rotor
- Wound Rotor Construction
Should Cost Models for Machined Parts
- Drilling
- Standard Twist Drilling
- Deep Hole Drilling
- Gun Drilling
- Pilot & Reaming
Tapping
- Hand Tapping
- Machine Tapping
- Blind Hole Tapping
- Thread Forming
Turning
- External Turning
- Facing on Lathe
- Grooving & Parting
- Thread Turning
Milling
- Face Milling
- Slot Milling
- Profile Milling
- End Milling
Threading
- Single-Point Thread Cutting
- Rolling Dies
- Thread Milling
- Facing
- Lathe Facing
- Plunge Facing
- Facing in Chuck Work
Broaching
- Internal Keyway Broaching
- External Surface Broaching
- Rotary Broaching
Grinding
- Surface Grinding
- Cylindrical Grinding
- Centerless Grinding
- Tool Grinding
Boring
- Line Boring
- Jig Boring
- Horizontal Boring
Notching
- Tube Notching
- Sheet Metal Corner Notching
- Angle Notching
- Laser Cutting
- Fiber Laser
- CO₂ Laser
- Pulse Laser for Microcutting
Honing
- Manual Honing
- Vertical Honing
- Plateau Honing (Automotive)
Gear Hobbing
- Spur Gear Hobbing
- Helical Gear Hobbing
- Spline Cutting via Hobbing
Gear Shaping
- Internal Gear Shaping
- External Gear Shaping
- Timing Gear Shaping
Gear Shaving
- Radial Infeed Shaving
- Diagonal Shaving
- Underpass Method
- Gear Grinding
- Profile Grinding
- Generating Grinding
- Form Grinding
Shot Blasting
- Steel Grit Blasting
- Wheel Blast Systems
- Shot Blast Cleaning
Shot Peening
- Air Blast Peening
- Gravity Peening
- Saturation Peening
Sand Blasting
- Suction Sandblasting
- Pressure Blasting
- Abrasive Media Selection
Lapping
- Flat Lapping
- Cylindrical Lapping
- Polishing and Final Finishing
Automotive Should Cost Models for Welding & Joining
- MIG / MAG Welding
- Carbon Steel MIG
- Stainless MAG
- Pulse MIG for Aluminum
TIG Welding
- Manual TIG
- Orbital TIG
- Thin Section Welding
- Spot Welding
- Projection Spot Welding
- Cross Wire Welding
- Resistance Spot Weld
Friction Stir Welding
- Aluminum Profile Joining
- Tool Steel Weld Head
- Automated Linear FSW
- Laser Welding
- Keyhole Welding
- Conduction Welding
- Fine Micro-Welds
Ultrasonic Welding
- Plastic Ultrasonic Welding
- Wire Splicing
- Battery Tab Welding
- Riveting / Clinching
- Solid Riveting
- Blind Riveting
- Mechanical Clinching
Should Cost Models for Surface Finishing in xcPEP
- Powder Coating
- Epoxy Powder Coat
- Polyester Powder Coat
- Hybrid Powder Finishes
Electroplating
- Nickel Electroplating
- Zinc Plating
- Chrome Plating
- Anodizing
- Type II Color Anodizing
- Type III Hard Anodizing
- Clear & Black Coatings
Galvanizing
- Hot-Dip Galvanizing
- Electrogalvanizing
- Dry Coating Post-Galv
- Passivation
- Citric Acid Passivation
- Nitric Acid Process
- Stainless Steel Surface Prep
- Deburring & Polishing
- Tumbler Finishing
- Vibratory Deburring
- Buffing & Brushing
Should Cost Models for Testing & Inspection Process in xcPEP – Should Cost Analysis Tool
- Dimensional Inspection
- CMM Inspection
- Height Gauge / Vernier
- Go/No-Go Gauge
Visual Inspection
- Manual Surface Check
- Visual Defect Sorting
- Deflash / Burr Check
- X-Ray & CT
- Die-Cast Void Inspection
- Battery Cell CT Scan
- BGA Package X-Ray
- Hardness & Microstructure
- Rockwell / Vickers Testing
- Metallographic Etching
- Grain Size Analysis
- Leak & Pressure Testing
- Helium Leak Test
- Air Decay Test
- Hydrostatic Pressure Test
Should Cost Models for Automotive Packaging & Logistics in xcPEP – Cost Analysis Platform
- Export Packaging
- Palletized Crates
- Heat-Treated Wood (ISPM 15)
- Heavy-Duty Shrink Wrap
Returnable Packaging
- Plastic Bin Systems
- Metal Returnable Cages
- Foldable Crates
- Thermoformed Trays
- Anti-Static Trays
- Custom Molded Cavities
- Conductive Tray Systems
- Labeling & Identification
- Barcode Printing
- Part ID & QR Labels
- Compliance Tagging (RoHS, REACH)
- Final Assembly Packing
- Subassembly Kits
- Cushioned Inserts
- Operator Instruction Leaflets
Automotive Miscellaneous Should Cost Models in xcPEP, should cost modelling software
- Booklet
- Saddle Stitch Binding
- Perfect Binding
- Wiro Binding
- Folded Leaflet Assembly
- UV Coating & Lamination
Composite
- Prepreg Layup
- Vacuum Bagging
- Resin Transfer Moulding (RTM)
- Autoclave Curing
- Filament Winding
- Fabric – Rexine
- Heat Embossing
- Pattern Cutting
- Stitching & Overlocking
- Surface Coating
- PVC/PU Backing Lamination
Glass Sheet Manufacturing
- Float Glass Process
- Annealing & Cutting
- Coating & Tempering
- Silk Screen Printing
- Mirror Backing Application
- Glass Moulding
- Press & Blow Moulding
- Injection Blow Moulding
- Rotary Moulding
- Hot Mould Preheating
- Annealing Tunnel Furnace
Paper Packaging
- Corrugated Box Forming
- Die Cutting & Slotting
- Folding & Gluing
- Printed Sleeve Application
- Pulp Moulded Tray
- Substrate – Ceramic
- Alumina Ceramic Substrates
- Green Tape Lamination
- Laser Scribing
- Firing & Metallization
- Direct Bonded Copper (DBC)
Wood
- Plywood Cutting
- Edge Banding
- Laminate Pressing
- Routing & CNC Machining
- Surface Polishing