Automotive Cost Reduction Studies

ASI Engineering tears down your vehicle and the competitor vehicle side by side. Every part is scanned, measured, and digitally mapped using high-resolution tools. Wall thickness, feature depth, and projected area are captured for both sets of parts and pushed into xcPEP, our should costing software. This gives us a clean, structured view of how geometry choices impact cost. When a competitor uses less material or avoids secondary operations, xcPEP, our cost modelling software highlights that exact region—pinpointing how and where your design can be optimised to reduce cost.

Material samples from both vehicles are lab tested by ASI Engineering using XRF, density checks, and chemical analysis. We do not rely on assumed grades or supplier claims. Every confirmed grade is linked to regional prices from xcPROC, our should cost database inside xcPEP. The material cost delta is no longer a guess. It becomes a clear, actionable gap. If the competitor achieves the same strength using a lower-cost alloy or polymer, xcPEP, our should cost software calculates exactly how much cost you can save by switching, backed by real-world should cost data.

For each part, ASI Engineering models the real manufacturing route including stamping, molding, welding, machining, and painting. We enter exact parameters into xcPEP such as tool life, scrap, OEE, and cycle time for both vehicles. Instead of generic estimates, we compare true process logic to uncover cost drivers. If the competitor builds the same part using fewer steps or a faster process, xcPEP shows you the exact value of making the same change.

Our team maps the actual machine class used for each operation including tonnage, power, and capability. xcPEP calculates machine hour cost from capital, energy, and maintenance. This lets us compare what machine the competitor would use versus yours. If the competitor part is built on a more efficient setup, we show the cost saving you can realise by making a similar shift.

ASI Engineering identifies the actual skill level and manpower needed for each process step. Using xcPROC regional wage data, xcPEP calculates the labour hour cost for both vehicles. Where the competitor uses fewer operators or a simpler join method, the savings are visible. This helps your team understand where labour complexity is adding cost and what process simplifications are possible.

We model the exact packaging style, stack density, and transport route for each part. xcPEP simulates cost based on load fill, distance, and duty for both sourcing cases. If the competitor has reduced freight cost by localising a supplier or optimising packaging, the platform quantifies the benefit so you can adopt a similar strategy.

For any globally sourced part, xcPEP applies current exchange rates and associated charges. This allows ASI Engineering to isolate how much of your cost delta is driven by currency exposure. Where competitors have lower volatility or better cost control through localisation, we surface that insight as a savings opportunity.

Overheads like setup time, quality checks, and indirect manpower are calculated from actual hours, not percentages. xcPEP breaks down each component of overhead for your part and the competitor part. ASI Engineering shows which overheads are inflating cost and how the competitor avoids them. This gives you a clear target for efficiency gains.