# Advanced Structures India > Should Costing Revolution --- ## Pages - [Unlocking EBITDA: Engineering-Led Cost Transformation for Portfolio Companies](https://advancedstructures.in/unlocking-ebitda-engineering-led-cost-transformation-for-portfolio-companies/): Unlock hidden value in your manufacturing portfolio. ASI provides Private Equity firms with data-driven cost engineering, using proprietary tools to deliver actionable insights & drive EBITDA. - [Off Highway](https://advancedstructures.in/off-highway/): Off Highway Our core SaaS platforms, xcPEP and xcPROC, are purpose-built to tackle the unique cost challenges of off-highway vehicle... - [Off Highway Vehicles Should Costing](https://advancedstructures.in/off-highway/should-costing/): ASI Engineering delivers should costing for tractors, heavy and construction equipment using process-based cost models and region wise cost data. - [Off Highway Vehicles Cost Reduction](https://advancedstructures.in/off-highway/cost-reduction-by-benchmarking-and-should-costing/): Off-Highway Vehicles Benchmarking & Cost Reduction Cost reduction studies across off-highway, agricultural, construction, and mining platforms ASI Engineering delivers platform-level... - [Home Appliances Should Costing](https://advancedstructures.in/home-appliances/should-costing/): Part-level should costing for refrigerators, ovens, ACs, mixers, washing machines & more. Home appliances should costing using our should cost tool. - [Home Appliances](https://advancedstructures.in/home-appliances/): Home Appliances ASI Engineering is one of the few dedicated cost engineering teams in the world serving home appliance makers... - [Consumer Electronics Cost Reduction](https://advancedstructures.in/consumer-electronics/cost-reduction-by-benchmarking-and-should-costing/): Consumer Electronics Benchmarking & Cost Reduction A teardown-led approach to find real savings ASI Engineering performs a complete teardown of... - [Contact](https://advancedstructures.in/contact-advanced-structures-india/): Contact us to explore xcPEP should-costing SaaS, set up a cost lab, or for custom cost-engineering projects. Email sales@advancedstructures.in today - [Consumer Electronics](https://advancedstructures.in/consumer-electronics/): Consumer Electronics In the fast-moving world of consumer electronics, understanding what drives cost at the board and EMS level is... - [Consumer Electronics Should Costing](https://advancedstructures.in/consumer-electronics/should-costing/): ASI Engineering uses xcPEP, the should-cost analysis software, to accurately model part-level costs for consumer electronics should costing. - [Careers](https://advancedstructures.in/careers/): Join our Bengaluru team to build xcPEP, should costing Software powering automotive, electronics, EVs & more. Grow fast with 6-month appraisals. - [Automotive Should Costing](https://advancedstructures.in/automotive/should-costing/): Automotive should costing by ASI Engineering with xcPEP - should cost tool, with detailed should cost models, transparent cost breakdowns & more. - [Automotive Cost Reduction by Benchmarking and Should Costing](https://advancedstructures.in/automotive/cost-reduction-by-benchmarking-and-should-costing/): Reduce manufacturing cost across cars, trucks & more through should costing powered by xcPEP, software for cost reduction in automotive industry. - [Should Costing Lab Build Operate Transfer](https://advancedstructures.in/xcpep-should-cost-analysis-software/lab-build-operate-transfer/): Set up your in-house should costing lab with ASI. We deploy xcPEP, train your team, migrate cost models, and hand over a fully operational lab. - [xcPEP Deployment & Training](https://advancedstructures.in/xcpep-should-cost-analysis-software/deployment-training/): Deploy xcPEP with ASI: we configure it to your needs, create cost models, migrate data, and train your team to perform should costing using xcPEP. - [xcPROC](https://advancedstructures.in/xcproc-costdata/): Explore xcPROC —a database with material, machine, labor, and process costdata for accurate, region-specific should-costing - [xcPEP Cost Engineering SaaS](https://advancedstructures.in/xcpep-should-cost-analysis-software/): xcPEP is a purpose-built should cost analysis software with real-time, editable cost models designed for engineering, sourcing and finance teams. - [Automotive](https://advancedstructures.in/automotive/): Automotive should costing done by ASI Engineering using xcPEP, our should cost model software for target costing, benchmarking & cost reduction. - [About Us](https://advancedstructures.in/about-advanced-structures-india/): Learn about Advanced Structures India, creators of xcPEP should-cost software and xcPROC cost data, built for real world, scalable should costing. - [Home](https://advancedstructures.in/): Advanced Structures India delivers accurate, scalable Should Costing through the xcPEP® SaaS platform and the xcPROC® cost data platform. --- ## Posts - [Refrigerator Should-Costing & Teardown Analysis with xcPEP](https://advancedstructures.in/teardown-should-cost-analysis-bom-direct-cool-refrigerator/): This study reveals a full refrigerator should costing & teardown analysis, BOM, cost drivers, and sourcing insights for Direct Cool single door fridges. - [Refrigerator Compressor Should Costing & Benchmarking: BOM, Cost Drivers and Procurement Insights](https://advancedstructures.in/refrigerator-compressor-should-costing-benchmarking/): Refrigerator compressor teardown and should costing with BOM details, component weights, cost drivers, and benchmarking analysis - [How to do Should Costing of Semiconductor Packaging?](https://advancedstructures.in/how-to-do-should-costing-of-semiconductor-packaging/): Detailed should costing of semiconductor packaging shows how each step - die attach, bonding, molding, testing - contributes to IC packaging costs. - [Built for the Real World: A Modern Alternative to Legacy Should Costing Software](https://advancedstructures.in/xcpep-best-should-costing-software/): Explore xcPEP, a modern should costing software that outperforms legacy costing tools with faster performance and region-specific accuracy. - [Deep Dive into 55HP Agricultural Tractor Part Should Costing & Benchmarking](https://advancedstructures.in/tractor-cost-analysis-should-costing-benchmarking/): Explore our in-depth teardown and should costing analysis of a 55HP agricultural tractor. Learn how to reduce tractor costs, optimize part manufacturing, and achieve significant savings through expert benchmarking and value engineering strategies - [The Definitive Guide to Electronics Should Costing in Automotive, EV, and Off-Highway Industries: Master Cost Control and Drive Innovation](https://advancedstructures.in/how-to-should-cost-electronics-automotive-ev/): Unlock significant cost savings in automotive, EV, and off-highway electronics. This comprehensive guide details should costing methodologies, from teardown analysis to AI-powered predictive costing, and shows how xcPEP software empowers cost control and innovation for maximum profitability. - [Mastering Global Sourcing: How Advanced Cost Intelligence and Verified Data Transform Commodity Management](https://advancedstructures.in/global-commodity-managers-should-cost-software/): Discover how xcPEP should cost analysis software empowers global commodity managers. Solve sourcing pain points, achieve cost optimization, and leverage real-time cost intelligence for strategic advantage. - [Hydraulic Motor Teardown and Should Cost Analysis](https://advancedstructures.in/hydraulic-motor-teardown-and-should-costing/): Deep-dive teardown and cost analysis of a hydraulic motor. Includes internal component breakdown, BOM, and should-cost estimation to guide sourcing... - [Omron BP Monitoring Device HEM-7120 Teardown, BOM and Should Costing](https://advancedstructures.in/omron-bp-monitoring-device-hem-7120-teardown-bom-and-should-costing/): Detailed teardown and Bill of Materials (BOM) analysis of the Omron HEM-7120 digital blood pressure monitor. Understand manufacturing costs and... - [Mi PowerBank 3i Teardown and Costing](https://advancedstructures.in/mi-powerbank-3i-teardown-and-should-costing/): We have conducted a detailed teardown of a power bank, mapped its bill of material and calculated its should cost. - [Bluetooth Earphone Teardown, BOM and Costing](https://advancedstructures.in/bluetooth-earphone-teardown-bom-should-costing/): We have conducted a detailed teardown of a bluetooth neckband headphone, mapped its bill of material and calculated its should cost. - [BLDC Hub Motor Teardown & Should Costing](https://advancedstructures.in/bldc-brushless-direct-current-hub-motor-teardown-detailed-comparison-for-cost-reduction-insights/): Our engineers have benchmarked a BLDC motor used in an electric scooter to study its design, BOM and then conducted a zero-based costing exercise on it to get its direct material cost. - [EV Battery Pack Teardown Study](https://advancedstructures.in/ev-battery-pack-teardown-study-should-costing/): This is a blog about benchmarking features, BOM and architecture of an electric vehicle battery pack. This also includes study of all direct costs of the li ion EV battery pack by zero based costing method. - [EV Charger Teardown & Cost Driver Comparison](https://advancedstructures.in/ev-charger-teardown-cost-driver-comparison/): This is a blog about benchmarking features, BOM and architecture of an electric vehicle charger. This also includes study of all direct costs of the EV charger by zero based costing method. - [Xiaomi Smart LED TV 43” Teardown, BOM and Should Costing](https://advancedstructures.in/xiaomi-smart-led-tv-43-teardown-bom-and-should-costing/): Detailed teardown and BOM analysis of Smart TV 43. Explore LED TV component costs, and manufacturing insights. - [LCV Steering Pump Teardown & Should Costing](https://advancedstructures.in/lcv-steering-pump-teardown-benchmarking-should-costing/): This is a blog about benchmarking features, BOM and architecture of an automotive power steering pump. This also includes study of all direct costs of the hydraulic steering pump by zero-based costing method. - [Catalytic Converter Benchmarking for Rare Earth Element Loading and Cost](https://advancedstructures.in/benchmarking-should-costing-catalytic-converter-substrates-for-manufacturing-cost-and-rare-earth-element-loading/): Our engineers tore down a catalytic convertor to study its design, materials and then conducted a zero based costing activity on all parts including rare earth element loading in the substrate. - [ADAS Radar Sensor Teardown & Should Costing](https://advancedstructures.in/continental-ars-4-b-radar-sensor-teardown-and-should-costing/): This is a blog post about how we've torn down and benchmarked an ADAS radar sensor to study its construction and then conducted a zero-based costing activity on it. - [Kitchen Chimney Teardown & Should Costing](https://advancedstructures.in/elica-chimney-efl-s601-benchmarking-teardown-should-costing/): How to do teardown benchmarking and zero based costing of a home appliance like kitchen chimney. - [DJI Inspire 1 Drone Teardown and Costing](https://advancedstructures.in/dji-inspire-1-drone-teardown-and-should-costing/): We benchmarked a DJI Inspire 1 drone to study its design and direct cost. This study also included a detailed zero-based costing exercise of all the drone components. - [Starter Motor Teardown and Feature Study](https://advancedstructures.in/starter-motor-teardown-should-costing-and-feature-study/): This is a blog about benchmarking features, BOM, architecture and zero-based costing of an automotive starter motor. - [PCB Teardown Benchmarking & Cost Reduction Insights](https://advancedstructures.in/pcb-teardown-benchmarking-cost-reduction-insights/): This is a blog about benchmarking features, BOM and architecture of an automotive PCB. This also includes study of all direct costs of the PCB by zero based costing method. - [Motor Controller Teardown & Cost Driver Comparison](https://advancedstructures.in/motor-controller-teardown-should-costing-and-cost-driver-comparison/): This is a blog about benchmarking features, BOM and architecture of an electric vehicle motor controller unit MCU. This also includes study of all direct costs of the MCU by zero based costing method. --- # # Detailed Content ## Pages > Unlock hidden value in your manufacturing portfolio. ASI provides Private Equity firms with data-driven cost engineering, using proprietary tools to deliver actionable insights & drive EBITDA. - Published: 2025-08-01 - Modified: 2025-08-19 - URL: https://advancedstructures.in/unlocking-ebitda-engineering-led-cost-transformation-for-portfolio-companies/ Driving Portfolio Value for Private Equity ASI Engineering's precision approach to manufacturing cost reduction. Unlocking EBITDA Engineering-Led Cost Transformation for Portfolio Companies Challenge ASI Solution Value Key Challenges Opaque cost structures for high value parts Volatile input costs Scattered data across teams Limited visibility into drivers Our Framework Part-level costing using xcPEP Supplier cost mapping via xcPROC Should Costing of each and every part Unified data layer for decision-making Business Impact EBITDA uplift Faster time-to-insight Improved exit multiples Sustained competitive edge Core Technology Platforms xcPROC Procurement Intelligence xcPEP Costing Engine Precise Should Costing xcPEP Idea Module Automated Design & Commercial Idea Generation Build - Operate - Transfer Engagement Model Phase 1: Build Detailed Should-Costing Foundation Phase 2: Operate Idea Generation & Implementation Phase 3: Transfer Cost Engineering Function Handover Data mapping from drawings and teardown Teardown analysis of proprietary and competitor products Alignment of cost models with company's reality Development of raw material, LHR, MHR databases aligned to company’s products and supply chain Supplier & route mapping Should costing of everything the company makes and buys Engineering idea generation: design / material / supplier / process / packaging changes Engineering idea implementation Commercial idea generation: negotiation gaps, alternate suppliers, import/export data Commercial idea implementation Cost Engineering Function is created inside the company Full handover of platform and processes Training, documentation, and continued support Deliverables & Outcomes Immediate Baseline costing Quick-win ideas Medium-Term Operational improvement Margin expansion Long-Term Exit readiness Value creation The Private Equity Imperative: Unlocking Value in Manufacturing Assets The Challenge: Navigating Complexity and Cost PressuresPrivate Equity firms investing in manufacturing assets frequently encounter challenges that obscure true cost drivers and impede value maximization. These include the complexity of diverse manufacturing processes, the volatility of global supply chains, fluctuating raw material prices, and dynamic labor costs across regions. "Traditional analytical methods often prove inadequate in penetrating this opacity, leaving PE firms with a limited view of the granular opportunities for cost reduction and performance enhancement. " "The inherent complexity of manufacturing, exacerbated by global dynamics, creates a 'black box' effect for Private Equity firms. " This opacity hinders accurate valuation, risk assessment, and the identification of true value creation levers. Without a clear and granular understanding of the cost structure, it becomes challenging to pinpoint specific inefficiencies or to accurately assess the true potential for operational improvement within an acquired asset. This lack of clarity can also lead to misjudgments in valuation during acquisition, increasing investment risk and limiting the ability to maximize returns post-acquisition, as the levers for value creation remain hidden or poorly understood. The Opportunity: Strategic Cost Reduction and Performance Enhancement"For Private Equity, strategic cost reduction and performance improvement are not merely about cutting expenses; they are fundamental levers for enhancing EBITDA, improving operating margins, and ultimately maximizing enterprise value upon exit. " The significant opportunity lies in identifying and executing precise, data-driven interventions that yield sustainable financial returns, transforming manufacturing assets into highly efficient, profitable entities. The pursuit of this opportunity is often constrained by the quality and granularity of available data. A lack of precise cost intelligence means that even well-intentioned cost-cutting initiatives can be broad-brush, potentially impacting product quality, innovation, or long-term value, rather than surgically targeting inefficiencies. "This can lead to short-term gains at the expense of long-term sustainability or product quality, ultimately devaluing the asset in the eyes of future buyers. " It also creates a cycle of reactive cost-cutting rather than proactive optimization, underscoring the need for a more sophisticated approach to identifying and realizing value. Advanced Structures India: A New Paradigm for Value Creation Beyond Traditional Consulting: Our Technology-Driven DifferentiatorTraditional management consulting firms and generic benchmarking companies often provide high-level strategic advice or static, aggregated data. While these services hold value, their methodologies frequently lack the granular, real-time, and engineering-led precision essential for unlocking deep-seated value in complex manufacturing operations. "Advanced Structures India (ASI) fundamentally shifts this paradigm by prioritizing technology as the core enabler of cost engineering. " "ASI's primary focus is on building and deploying proprietary cost engineering technology, xcPEP and xcPROC, rather than solely selling project engagements or database subscriptions. " This approach aims to onboard Private Equity portfolio companies onto their powerful platforms, empowering them with internal capabilities for continuous cost optimization. "Unlike generic platforms that rely on broad industry averages, xcPROC provides granular, part-level data tied to real manufacturing contexts, including tooling, cycle times, material yields, and live market rates, ensuring a transparent and defensible cost model that mirrors shop-floor reality. " "Furthermore, ASI regularly develops fully customized datasets tailored to a client’s specific parts, processes, and geographies, which are maintained exclusively for that organization. ""This shift from 'consulting as a service' to 'technology as an enabler' represents a fundamental re-risking of value creation for Private Equity firms. " "By internalizing the capabilities through... --- - Published: 2025-05-02 - Modified: 2025-08-19 - URL: https://advancedstructures.in/off-highway/ Off Highway Our core SaaS platforms, xcPEP and xcPROC, are purpose-built to tackle the unique cost challenges of off-highway vehicle manufacturers : low volumes, high customization, and a heavy reliance on sourced components. Backed by our in house services team - ASI Engineering, one of the few dedicated cost engineering teams in the world, we provide support to ensure successful adoption, data quality, and continuous cost reduction across complex, low-volume programs. For over 5 years, we have been working regularly with off‑highway OEMs addressing lower production volumes, a high mix of purchased or proprietary parts, complex castings and forgings, hydraulic systems, stringent durability requirements, rugged operating environments, and long product lifecycles. Machines Target costing and cost benchmarking Geographies Considered for costing parts of a single machine by mapping its entire supply chain. And more data points In a typical target costing or cost reduction study. Below are turnkey services where we partner with off‑highway OEMs on a project basis. All offerings are delivered through xcPEP and xcPROC. Should Costing We use engineering drawings or teardowns to deliver precise should-cost estimates for castings, hydraulics, weldments, and systems. Cost Reduction Studies We benchmark your machine with your competitors to uncover cost-saving opportunities in materials, processes, labour & supply chain. xcPEP Deployment We tailor xcPEP to your products, suppliers, locations, and build custom raw material, MHR, and LHR datasets. Cost Lab Build-Operate-Transfer We set up a cost lab, create SOPs, train your team on live projects, and deliver a fully functional setup. Deployment and Cost Lab Build-Operate-Transfer are services through which the ASI Engineering team ensures xcPEP is properly configured and effectively utilized. How are we different? We build cost engineering technology. Our core products, xcPEP for should cost modelling and xcPROC for cost data, form a powerful ecosystem supported by engineering services that speed customer adoption. While we may resemble consulting or benchmarking firms, the similarity is only superficial; our strength lies in the technology we create. ASI vs. Management Consultants vs. Benchmarking Companies Approaches to Cost Optimization for Off-Highway Equipment Manufacturers ASI – Engineering-Led Cost Transformation Management Consultants Benchmarking Companies Engineering-led cost transformation using xcPEP & xcPROC, tailored for tractors, construction, and agricultural equipment. Focus on sustainable, structural cost reduction across full product lifecycles. Strategy-focused consulting aimed at solving isolated problems. Engagements are billable-hour driven and often lead to recurring cost challenges. No pre-existing off-highway equipment database. Deliverables based on expensive, one-off teardown or reverse-engineering projects. Transparent Should Costing for every part, adapted to each manufacturer’s supply base and production process. Highly detailed, data-driven simulations enabling targeted cost-reduction initiatives. Relies on SME expertise and generic industry data. Often produces incremental changes without addressing systemic cost drivers. Costing often based on simplistic formulae from limited teardown samples. Insights rarely capture the complexity of heavy-duty off-highway components. Proprietary platforms: xcPEP – high-detail part costing & simulation xcPROC – procurement intelligence & sourcing support Optimized for the heavy-duty manufacturing environment. General financial models and operational frameworks. Lacks manufacturing-specific cost simulation capabilities. Uses ad-hoc analysis tools for each engagement. No scalable platform for repeatable, accurate cost estimation. Measurable, sustainable cost reductions with direct impact on margin and competitiveness. Recommendations improve current state but may not deliver optimal or lasting results. Outcomes are slow, costly, and often fail to justify the investment. Rapid portfolio-wide analysis with live costing tools – weeks, not months. Multi-month projects from start to final report. Slow, custom project timelines with long lead times for any usable insights. Our Core Objective Engineering Led Cost Transformation Of Off-Highway OEMs and Tier 1 Suppliers Challenge ASI Solution Value Key Challenges Opaque cost structures for high value parts Volatile input costs Scattered data across teams Limited visibility into drivers Our Framework Part-level costing using xcPEP Supplier cost mapping via xcPROC Should Costing of each and every part Unified data layer for decision-making Business Impact EBITDA uplift Faster time-to-insight Improved exit multiples Sustained competitive edge Core Technology Platforms xcPROC Procurement Intelligence xcPEP Costing Engine Precise Should Costing xcPEP Idea Module Automated Design & Commercial Idea Generation Build - Operate - Transfer Engagement Model Phase 1: Build Detailed Should-Costing Foundation Phase 2: Operate Idea Generation & Implementation Phase 3: Transfer Cost Engineering Function Handover Data mapping from drawings and teardown Teardown analysis of proprietary and competitor products Alignment of cost models with company's reality Development of raw material, LHR, MHR databases aligned to company’s products and supply chain Supplier & route mapping Should costing of everything the company makes and buys Engineering idea generation: design / material / supplier / process / packaging changes Engineering idea implementation Commercial idea generation: negotiation gaps, alternate suppliers, import/export data Commercial idea implementation Cost Engineering Function is created inside the company Full handover of platform and processes Training, documentation, and continued support Deliverables & Outcomes Immediate Baseline costing Quick-win ideas Medium-Term... --- > ASI Engineering delivers should costing for tractors, heavy and construction equipment using process-based cost models and region wise cost data. - Published: 2025-05-02 - Modified: 2025-07-30 - URL: https://advancedstructures.in/off-highway/should-costing/ Advanced Should Costing for Tractors, Heavy & Construction Equipment Executed by ASI Engineering using xcPEP, Should Costing Software. Should costing plays a critical role in off-highway programs—especially where high part costs, low production volumes, and sourcing spread across multiple regions make cost control particularly challenging. Off-highway platforms—including excavators, tractors, construction equipment, and heavy machinery such as wheel loaders and mining trucks—are built through diverse, cost-intensive manufacturing processes. Precision-dependent operations like heavy casting, welded structures, hydraulic machining, and multistage drivetrain fabrication introduce cost drivers that vary with batch size, routing, and geography. These drivers are not captured in BOM rollups or spreadsheet tools, making structured should costing methodology essential—grounded in real manufacturing process logic and region-specific input cost data. ASI Engineering undertakes complete should costing projects for OEMs and suppliers—delivering part-level cost data, process logic, and manufacturing breakdowns using detailed should cost models. Our team supports sourcing and design decisions with actionable insights for tractors, heavy equipment, and construction machinery. Challenges and limitations of legacy tools in - Off-Highway Should Costing Off-highway vehicles use large castings, welded frames, hydraulic systems, and complex drivetrains. Parts are built in low to mid volumes, with cost driven by setup time, scrap, inspection, and regional sourcing. This mix of processes and production realities makes costing difficult to generalize. . Should costing for tractors is especially difficult because parts often span low volumes, welded sub-assemblies, and casting-heavy drivetrains—introducing high cost variability across plants, suppliers, and regions. Traditional tools cannot handle this complexity. Excel breaks down when routing or region changes. Legacy software depends on clean CAD and fixed templates that do not match off-highway manufacturing. Consulting reports offer one-time estimates but cannot support internal teams on an ongoing basis. ASI Engineering approaches this differently. Every project we execute is built on process level understanding and real-world inputs. We create models from the ground up, based on actual manufacturing operations and region-specific rates. Routings are assigned with care, reflecting how the part would be made in practice, not in theory. We account for cycle time, scrap, setup, and labour variation to reflect how cost behaves across suppliers, volumes, or geographies. The result is a structured, reusable model that gives sourcing and engineering teams a reliable cost reference, not just a one time number. Consulting reports, legacy tools, and spreadsheets may give you a number, but not the real cost. ASI Engineering shows how the part is actually made, and what it should truly cost. The Same Part Can Be Made in Different Ways In off-highway manufacturing, the same part can be made using different combinations of processes depending on the plant, available machinery, tooling setup, and batch size. A gearbox housing might be cast in one case or machined from solid in another. A frame may be fabricated from plate in one plant or assembled from cast modules in another. There is no single fixed path to production. This variability makes it impossible to use a templated costing approach. Tools that rely on predefined routings or generic formulas do not capture how the part is actually made. Every operation sequence must be built from real manufacturing logic — which Excel, static BOM tools, or high-level reports cannot replicate. This variability is a major reason why structured should costing for tractors is essential—ensuring plant-specific processes and cost drivers are captured accurately. Production Volume Drives Cost Behavior Not all off highway parts are built in small quantities. Common components like housings or transmissions may run in high daily volumes, while others such as boom arms, brackets, or model specific hydraulics are produced in smaller batches. At lower volumes, setup time, fixture cost, and overhead absorption start to dominate cost. Many costing tools assume stable, high volume production where cycle time and material drive pricing. But off highway programs often combine both scales, and unless costing accounts for volume effects, the output remains disconnected from how cost actually behaves in production. This is particularly important in should costing for heavy equipment, where cost models must reflect volume-sensitive operations like welding and assembly of structural parts. Region and Plant-Level Inputs Matter The cost of the same part changes drastically depending on where it is made. Hourly wages, energy tariffs, machine depreciation, indirect labour ratios, and even downtime norms vary by country and plant. A housing machined in Europe does not cost the same as one machined in India, even if the process steps are identical. Most tools either apply standard rates or depend on user inputs that rarely get updated. Without region-specific data for each process and operation, even a detailed cost structure becomes disconnected from sourcing reality. Accurate should costing for construction equipment requires region-specific cost inputs to reflect real manufacturing conditions across global supplier bases. Most Off-Highway Parts Involve More Than One Process Off-highway parts are often built through... --- - Published: 2025-05-02 - Modified: 2025-07-30 - URL: https://advancedstructures.in/off-highway/cost-reduction-by-benchmarking-and-should-costing/ Off-Highway Vehicles Benchmarking & Cost Reduction Cost reduction studies across off-highway, agricultural, construction, and mining platforms ASI Engineering delivers platform-level cost reduction by tearing down full off-highway systems, modelling them in xcPEP, and identifying hidden savings through real manufacturing logic. Every simulation reflects actual plant operations, helping teams reduce cost with confidence. Off-Highway Vehicles Benchmarking & Cost Reduction Engineering-led cost savings across enclosures, motors, insulation, wiring, and controls—powered by teardown data, detailed cost models, and real manufacturing logic. 1. Teardown benchmarking Of Customer's & Competitor's Vehicles 2. Should Costing Of Customer's & Competitor's Vehicles 3. Cost Reduction Idea Generation By analyzing cost gaps between customer's and competitor's vehicles. Off-Highway Cost Reduction Why it matters now more than ever Cost reduction has become a priority across agricultural, construction, and mining equipment due to tightening emissions norms, fluctuating input prices, and growing pressure from lower-cost competitors. Most programs still rely on top-down targets or BOM-level tracking, which miss true cost drivers hidden inside process flow, design decisions, and manufacturing complexity. Without detailed visibility at the part and process level, cost reduction remains inconsistent and reactive. You can’t reduce cost by just tracking it. You need to break it down and understand what’s behind it. Our Approach Engineering-Led Should Costing with xcPEP Our approach to cost reduction starts by tearing down your part alongside a competitor’s and understanding what drives the cost. We do not just report the total. We look at every part, every process, and every design choice to find where the cost can actually be reduced. This work is done by ASI Engineering using real manufacturing logic. Below are some of the major cost drivers we have seen repeatedly in off-highway platforms and where most of the savings usually come from. Optimizing weight and complexity Castings and Forgings We find most savings by reducing unnecessary weight and simplifying casting or forging shapes. Minor adjustments to thickness or material choice often significantly cut production cost. Streamlining tolerances and setups Machined Components Savings typically come from relaxing overly tight tolerances and optimizing machining setups. Adjusting unnecessary precision levels directly reduces machining time and cost. Reducing labor and complexity Welding and Assembly We regularly achieve savings by simplifying weld joints and assembly sequences. Reducing manual labor through better design and automated welding cuts overall production expenses. Consolidating suppliers and designs Hydraulic Systems Major savings usually arise from consolidating suppliers and standardizing hydraulic components. Eliminating redundant or overly complex designs significantly lowers costs. Simplifying design and processes Powertrain Components Most savings in powertrain components come from eliminating unnecessary complexity in gear designs and assembly processes. Selecting more cost-effective materials also significantly reduces expenses. Reducing material and complexity Chassis & Structural Frames We typically identify savings by highlighting excess material and unnecessary fabrication steps, directly reducing cost without affecting durability. Should Costing in xcPEP Covers detailed should costing of every part's raw material, manufacturing process and overheads. Off-Highway Costing in xcPEP xcPEP is tailored specifically for off-highway vehicles where precision matters, manufacturing processes are complex, and cost visibility is critical. Using detailed teardown-derived data, xcPEP maps exact material usage, machining operations, welding processes, assembly steps, and supplier-specific cost variables. Every component—from castings, forgings, and machined parts to hydraulics and electrical harnesses—is costed using actual manufacturing logic and accurate regional data from xcPROC. Process flows reflect realistic shop-floor scenarios, enabling precise cost analysis and scenario simulation. Designed for tractors, construction machinery, mining equipment, and specialized off-highway vehicles, xcPEP allows detailed component-level costing and reliable decision-making across product lines and design variants. In depth costing of PCB ASI Engineering uses xcPEP to map every dimension and process involved in casting and forging large components. By simulating material use, tooling, and finishing steps, hidden cost drivers are surfaced, making it easy to spot where savings are possible. In depth costing of mechanical parts With xcPEP, every machined and fabricated part is costed using actual plant data. The platform highlights inefficiencies in machining cycles, tolerances, and fabrication steps, helping teams focus on what can be streamlined or redesigned for lower cost. Massive Library of Cost Models With xcPEP, every machined and fabricated part is costed using actual plant data. The platform highlights inefficiencies in machining cycles, tolerances, and fabrication steps, helping teams focus on what can be streamlined or redesigned for lower cost. Precise Machine Database ASI Engineering leverages xcPEP’s process and machine database to use accurate regional machine hour rates and process costs. This precision ensures that savings identified are based on real-world manufacturing logic, not just averages. Scenario Costing: Instantly compare suppliers or regions xcPEP allows users to simulate supplier or region changes in one click. By shifting sourcing between regions or suppliers, teams can instantly see how costs change, making it easier to make fact-based sourcing decisions and unlock new savings. Analyse data in depth xcPEP... --- > Part-level should costing for refrigerators, ovens, ACs, mixers, washing machines & more. Home appliances should costing using our should cost tool. - Published: 2025-05-01 - Modified: 2025-07-30 - URL: https://advancedstructures.in/home-appliances/should-costing/ Home Appliances Should Costing - Fridges, Ovens, ACs, Washing Machines & More. Should Costing for refrigerators, washing machines, air conditioners, and kitchen appliances — executed by ASI Engineering using xcPEP. Home appliances are built using a combination of compressors, foamed cabinets, BLDC motors, control PCBs, and injection moulded plastics. These systems span electrical, thermal, and mechanical domains and often interact, where a change in one part can shift cost across multiple operations or suppliers. Accurate should costing is necessary to reflect this structure and capture the true cost behavior of each component. Cost control in these platforms is made difficult by multi-material assemblies, tooling-intensive parts, and regional sourcing variation. Standard costing tools rarely account for actual production methods or the process-level dependencies seen in appliance programs. ASI Engineering executes should costing for home appliance products. Each part is modelled based on its actual manufacturing method, using inputs from teardown, drawings, or CAD. Process flows are defined using real production logic, and region-specific input rates are applied from our xcPROC database. All cost models are executed and delivered inside xcPEP for internal use across sourcing, design, and benchmarking teams. Why consultants, Excel models, and legacy tools fail in Home Appliances Should Costing Should costing in appliances like washing machines, mixers, and microwaves is challenging because small changes affect multiple systems. In a washing machine, altering the tub size or spin speed changes motor winding, PCB logic, and bracket design. A different drum material can impact moulding time, assembly steps, and balance weight selection. These interactions are not visible in a standard BOM. Most teams still use Excel or static cost templates. These tools do not capture real manufacturing steps and often miss operations like vibration welding of detergent trays, over moulding of harness joints, or slot fill variation in BLDC motors. Consultants and benchmark providers typically apply average rates or flat percentages without tracing how the part is actually made. ASI Engineering builds detailed cost models for every system in a home appliance. Our team captures inputs from teardown, drawings, or CAD, then maps the manufacturing steps as they happen on the shop floor — including forming, winding, moulding, assembly, and testing. Region specific rates are applied using data from our xcPROC database. Each part is modelled based on how it is actually made, and the costing is delivered inside xcPEP for practical use by sourcing, design, and cost control teams. ASI Engineering captures how home appliances are actually built — mapping every manufacturing step so that each cost model reflects real production, not just part names and material types. 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... --- - Published: 2025-04-22 - Modified: 2025-08-19 - URL: https://advancedstructures.in/home-appliances/ Home Appliances ASI Engineering is one of the few dedicated cost engineering teams in the world serving home appliance makers as a major part of their business. For over five years, we've enabled organization-wide should costing and cost reduction across all products using our proprietary platforms, xcPEP and xcPROC. Since 2021, xcPEP has been constantly upgraded incorporating needs of home appliance makers - tackling higher percentage of proprietary parts, large number of SKUs, shorter product lifecycles and competition from vertically integrated Chinese brands. Cost Models Used in calculation of of PCB manfacturing processs. And more products torn down and costed And more products target costing done in last 5 years. And more data points Mapped for a typical split AC. Below are turnkey services where we collaborate with home appliance makers on focused cost initiatives. All services are delivered using xcPEP and xcPROC. Should Costing We build full product or part-level should-costs for assemblies like compressors, motors, PCBs, and housings using CAD, teardowns, and supplier RFQs. Cost Reduction Studies We benchmark your appliance with competitor across cost drivers to generate cost reduction ideas. xcPEP Deployment We configure xcPEP to your products, suppliers, and locations, building custom raw material, MHR, and LHR datasets. Cost Lab Build-Operate-Transfer We set up a cost lab, create SOPs, train your team on live projects, and ensure it's fully operational. Deployment & Cost Lab BOT are services where ASI Engineering team ensures xcPEP is configured and used effectively. How are we different? We build cost engineering technology. Our core products, xcPEP for should cost modelling and xcPROC for cost data, form a powerful ecosystem supported by engineering services that speed customer adoption. While we may resemble consulting or benchmarking firms, the similarity is only superficial; our strength lies in the technology we create. ASI vs. Management Consultants vs. Benchmarking Companies Approaches to Cost Optimization for Home Appliance Manufacturers ASI – Engineering-Led Cost Transformation Management Consultants Benchmarking Companies Engineering-led cost transformation using xcPEP & xcPROC, tailored for Home Appliance makers. Focus on sustainable, structural cost reduction across full product lifecycles. Strategy-focused consulting aimed at solving isolated problems. Engagements are billable-hour driven and often lead to recurring cost challenges. No pre-existing home appliance database. Deliverables based on expensive, one-off teardown or reverse-engineering projects. Transparent Should Costing for every part, adapted to each manufacturer’s supply base and production process. Highly detailed, data-driven simulations enabling targeted cost-reduction initiatives. Relies on SME expertise and generic industry data. Often produces incremental changes without addressing systemic cost drivers. Costing often based on simplistic formulae from limited teardown samples. Insights rarely capture the nuances specific to home appliance manufacturing like large number of SKUs, global supply chains, relatively smaller production volumes and shorter product lifecycles. Proprietary platforms: xcPEP – high-detail part costing & simulation xcPROC – procurement intelligence & sourcing support Optimized for the home appliance makers with high number of SKUs with relatively smaller production volumes environment. General financial models and operational frameworks. Lacks manufacturing-specific cost simulation capabilities. Uses ad-hoc analysis tools for each engagement. No scalable platform for repeatable, accurate cost estimation. Measurable, sustainable cost reductions with direct impact on margin and competitiveness. Recommendations improve current state but may not deliver optimal or lasting results. Outcomes are slow, costly, and often fail to justify the investment. Rapid portfolio-wide analysis with live costing tools – weeks, not months. Multi-month projects from start to final report. Slow, custom project timelines with long lead times for any usable insights. Our Core Objective Engineering Led Cost Transformation Of Home Appliance Makers Challenge ASI Solution Value Key Challenges Opaque cost structures for high value parts Volatile input costs Scattered data across teams Limited visibility into drivers Our Framework Part-level costing using xcPEP Supplier cost mapping via xcPROC Should Costing of each and every part Unified data layer for decision-making Business Impact EBITDA uplift Faster time-to-insight Improved exit multiples Sustained competitive edge Core Technology Platforms xcPROC Procurement Intelligence xcPEP Costing Engine Precise Should Costing xcPEP Idea Module Automated Design & Commercial Idea Generation Build - Operate - Transfer Engagement Model Phase 1: Build Detailed Should-Costing Foundation Phase 2: Operate Idea Generation & Implementation Phase 3: Transfer Cost Engineering Function Handover Data mapping from drawings and teardown Teardown analysis of proprietary and competitor products Alignment of cost models with company's reality Development of raw material, LHR, MHR databases aligned to company’s products and supply chain Supplier & route mapping Should costing of everything the company makes and buys Engineering idea generation: design / material / supplier / process / packaging changes Engineering idea implementation Commercial idea generation: negotiation gaps, alternate suppliers, import/export data Commercial idea implementation Cost Engineering Function is created inside the company Full handover of platform and processes Training, documentation, and continued support Deliverables & Outcomes Immediate Baseline costing Quick-win ideas Medium-Term Operational improvement Margin expansion Long-Term... --- - Published: 2025-04-20 - Modified: 2025-07-30 - URL: https://advancedstructures.in/consumer-electronics/cost-reduction-by-benchmarking-and-should-costing/ Consumer Electronics Benchmarking & Cost Reduction A teardown-led approach to find real savings ASI Engineering performs a complete teardown of your product alongside a competing device to understand how each design and manufacturing choice impacts cost. Electrical and mechanical components are mapped in detail, and costed using real production logic inside xcPEP. This direct comparison reveals cost gaps and highlights specific opportunities to optimise material selection, simplify assemblies, and reduce process waste — all without compromising product quality. Consumer Electronics Benchmarking & Cost Reduction Consumer electronics should costing is a cost engineering method used to determine the fair value of a product by analyzing the materials, labor, manufacturing processes, and overheads associated with all its parts. This includes electrical components such as printed circuit boards and each mounted element, as well as mechanical assemblies like housings, mounts, and enclosures. With should costing, consumer electronics companies can identify cost reduction opportunities, benchmark competitors, negotiate more effectively with suppliers using detailed cost insights, accelerate development timelines, and make smarter sourcing decisions to stay competitive in a volatile and cost-sensitive market. 1. Teardown benchmarking Of Customer's & Competitor's Vehicles 2. Should Costing Of Customer's & Competitor's Vehicles 3. Cost Reduction Idea Generation By analyzing cost gaps between customer's and competitor's vehicles. Challanges and limitations of methods in - Consumer Electronics Cost Reduction Studies Many platforms that claim to support cost reduction are built only to compare bill of materials data. They focus on part-level price differences without understanding how those costs arise. These tools rely on supplier quotes, apply generic databases, and produce savings deltas that lack technical depth. There is no teardown. Mechanical components are skipped, and assumptions are made from catalog values instead of real inputs. Key manufacturing factors like cycle time, tooling life, scrap, and regional overhead are left out entirely. Without this context, there is no root cause clarity. The result is a list of surface-level suggestions that may look convincing in a slide but fail when tested in production. Engineering and sourcing teams need actionable ideas based on real manufacturing—not abstract comparisons. You cannot reduce what you have not understood. True savings come only when every part is stripped down, costed correctly, and compared with its benchmark. Electronics Should Costing in xcPEP Every part is disassembled, mapped, and costed using actual process flow How ASI Engineering Uses xcPEP to Drive Savings xcPEP is ASI’s proprietary cost engineering platform specifically built to convert detailed teardown insights into clear and actionable cost savings. Every component inside a consumer electronics product, including complex PCBs, molded enclosures, connectors, buttons, and display modules, is analyzed and costed using precise manufacturing routes, real factory process logic, and validated region-specific data from xcPROC. This structured, methodical approach enables engineering and sourcing teams to pinpoint exact cost reduction opportunities, validate supplier quotations with confidence, benchmark competitor products, and drive real cost savings at each stage of the product lifecycle. By providing such granular insights, xcPEP ensures teams do not rely on assumptions, averages, or generic estimates, resulting in meaningful, measurable savings. In depth costing of PCB ASI Engineering uses xcPEP to identify cost drivers for every PCB by capturing exact process steps, material use, and cycle times. Teams clearly see savings opportunities like layout optimization, passive component reduction, or process step consolidation, enabling immediate cost reductions. In depth costing of mechanical parts ASI Engineering leverages xcPEP to break down the costing of mechanical components by precise manufacturing processes and real machine data. This reveals opportunities such as material substitution, process simplification, or improved tooling strategies, leading directly to lower production costs. Massive Library of Cost Models ASI Engineering maintains a comprehensive library of validated cost models within xcPEP tailored specifically to consumer electronics. Teams quickly benchmark new designs or sourcing decisions against reliable models, accelerating the discovery of cost reduction ideas. Precise Machine Database ASI Engineering utilizes xcPEP’s integrated machine database, ensuring every costing study is based on real utilization rates and exact production data. This ensures cost reduction analyses reflect true manufacturing conditions, enabling confident negotiations with suppliers. Scenario costing: Easily shift PCB sourcing from China to India ASI Engineering employs xcPEP’s scenario costing functionality to instantly compare different sourcing scenarios, such as shifting PCB production from China to India. Teams can quantify the exact cost impact, enabling informed decisions to optimize sourcing strategies and reduce supply chain costs. In depth data analysis for cost savings ASI Engineering provides structured and detailed cost analyses through xcPEP, going beyond simple averages. Granular insights on every part and manufacturing step enable teams to proactively identify previously hidden cost reduction opportunities. The captured data flows directly into xcPEP, where it enables side by side cost comparison between your product and competing devices. This structured input allows ASI Engineering to trace cost differences back to design, packaging, or layout... --- > Contact us to explore xcPEP should-costing SaaS, set up a cost lab, or for custom cost-engineering projects. Email sales@advancedstructures.in today - Published: 2025-04-17 - Modified: 2025-07-30 - URL: https://advancedstructures.in/contact-advanced-structures-india/ Contact Us For xcPEP SaaSPlease contact xcpep. sales@advancedstructures. in using your official email. For Custom ProjectsPlease contact sales@advancedstructures. in using your official email if you are reaching out from India. If you're contacting us from outside India, please email international. sales@advancedstructures. in using your official email. If a physical teardown is needed for costing, you may ship your product to us via a reliable courier service such as DHL or UPS. We will perform the costing and share the results through xcPEP. AddressAdvanced Structures India Private Limited,2B, 4th Phase,Bommasandra Jigani Link Road,Bommasandra Industrial Area,Bengaluru, Karnataka,India. PIN - 560099 Our Social MediaFollow us on LinkedIn and join our 54k strong community. We post our latest product studies and job openings on our LinkedIn page. Prospective VendorsPlease write to purchase@advancedstructures. in with your offerings. Please do not write to all our emails. Job ApplicantsPlease visit our careers page for current openings. Please do not write to unrelated email addresses. Careers at ASI --- - Published: 2025-04-17 - Modified: 2025-08-19 - URL: https://advancedstructures.in/consumer-electronics/ Consumer Electronics In the fast-moving world of consumer electronics, understanding what drives cost at the board and EMS level is critical. That’s where our SaaS platforms, xcPEP, Electronics should costing software and xcPROC, should cost data come in; giving teams the clarity they need to manage complexity, scale decisions, and stay ahead of cost pressures. ASI Engineering, one of the few global teams focused solely on cost engineering works with leading brands in costing, cost benchmarking and cost reduction studies. BOM cost sum alone isn’t enough. Every part of every SKU needs detailed, updated calculation of materials, manufacturing, logistics, forex, and overheads. xcPEP delivers that. Should Cost Models Used in calculation of PCB manufacturing process cost. And more products torn down and costed With more than half of them being EVs. And more data points Mapped for a typical LED TV Below are services where we engage with customers on a project basis. Our services are built on top of and delivered using xcPEP and xcPROC. Should Costing We deliver accurate should-costs for products or assemblies like PCBs, batteries, plastics, and displays using BOMs, 3D data, teardowns, and supplier benchmarks. Cost Reduction Studies We benchmark your product against competitor across cost drivers to generate cost reduction ideas. Onboarding We tailor xcPEP to your products, suppliers, and locations, and build custom raw material, MHR, and LHR datasets. Cost Lab B-O-T We set up a cost lab in your organization, develops SOPs, train your team through live projects and deliver a functional cost lab. Deployment & Cost Lab BOT are services where ASI Engineering team ensures xcPEP is configured and used effectively. How are we different? We build cost engineering technology. Our core products, xcPEP for should cost modelling and xcPROC for cost data, form a powerful ecosystem supported by engineering services that speed customer adoption. While we may resemble consulting or benchmarking firms, the similarity is only superficial; our strength lies in the technology we create. ASI vs. Management Consultants vs. Benchmarking Companies Approaches to Cost Optimization for Consumer Electronics Manufacturers ASI – Engineering-Led Cost Transformation Management Consultants Benchmarking Companies Engineering-led cost transformation using xcPEP & xcPROC, tailored for Consumer Electronics makers. Focus on sustainable, structural cost reduction across full product lifecycles. Strategy-focused consulting aimed at solving isolated problems. Engagements are billable-hour driven and often lead to recurring cost challenges. No pre-existing Consumer Electronics database. Deliverables based on expensive, one-off teardown or reverse-engineering projects. Transparent Should Costing for every part, adapted to each manufacturer’s supply base and production process. Highly detailed, data-driven simulations enabling targeted cost-reduction initiatives. Relies on SME expertise and generic industry data. Often produces incremental changes without addressing systemic cost drivers. Costing often based on simplistic formulae from limited teardown samples. Insights rarely capture the complexity of electronics manufacturing and electronics child part sourcing. Proprietary platforms: xcPEP – high-detail part costing & simulation xcPROC – procurement intelligence & sourcing support Highly detailed cost models for various electronics from most complicated PCBs to Semiconductor Packaging. General financial models and operational frameworks. Lacks manufacturing-specific cost simulation capabilities. Uses ad-hoc analysis tools for each engagement. No scalable platform for repeatable, accurate cost estimation. Measurable, sustainable cost reductions with direct impact on margin and competitiveness. Recommendations improve current state but may not deliver optimal or lasting results. Outcomes are slow, costly, and often fail to justify the investment. Rapid portfolio-wide analysis with live costing tools – weeks, not months. Multi-month projects from start to final report. Slow, custom project timelines with long lead times for any usable insights. Our Core Objective Engineering Led Cost Transformation Of Consumer Electronics Manufacturers Challenge ASI Solution Value Key Challenges Opaque cost structures for high value parts Volatile input costs Scattered data across teams Limited visibility into drivers Our Framework Part-level costing using xcPEP Supplier cost mapping via xcPROC Should Costing of each and every part Unified data layer for decision-making Business Impact EBITDA uplift Faster time-to-insight Improved exit multiples Sustained competitive edge Core Technology Platforms xcPROC Procurement Intelligence xcPEP Costing Engine Precise Should Costing xcPEP Idea Module Automated Design & Commercial Idea Generation Build - Operate - Transfer Engagement Model Phase 1: Build Detailed Should-Costing Foundation Phase 2: Operate Idea Generation & Implementation Phase 3: Transfer Cost Engineering Function Handover Data mapping from drawings and teardown Teardown analysis of proprietary and competitor products Alignment of cost models with company's reality Development of raw material, LHR, MHR databases aligned to company’s products and supply chain Supplier & route mapping Should costing of everything the company makes and buys Engineering idea generation: design / material / supplier / process / packaging changes Engineering idea implementation Commercial idea generation: negotiation gaps, alternate suppliers, import/export data Commercial idea implementation Cost Engineering Function is created inside the company Full handover of platform and processes Training, documentation, and continued support Deliverables &... --- > ASI Engineering uses xcPEP, the should-cost analysis software, to accurately model part-level costs for consumer electronics should costing. - Published: 2025-04-17 - Modified: 2025-07-30 - URL: https://advancedstructures.in/consumer-electronics/should-costing/ Consumer Electronics Should Costing Powered by xcPEP, Delivered by ASI Engineering ASI Engineering performs detailed should costing for consumer electronics—including smartphones, laptops, wearables, chargers, tablets, and related more—using xcPEP, our purpose built should-cost analysis software. . We work directly on complex product assemblies, mapping out every subcomponent, identifying materials and manufacturing routes, and building structured cost models that reflect real world sourcing and production logic. This work enables critical business decisions such as setting target costs for new programs, benchmarking competing products, validating supplier quotes, or preparing for commercial negotiations. We cost both electronics and mechanicals—including PCB assemblies, internal frames, housings, thermal blocks, display modules, connectors, antennas, buttons, and structural plastics used in consumer electronics. Whether it is evaluating a second source, comparing EMS options, or controlling costs across product cycles, ASI delivers clarity at the level of detail that high volume electronics programs demand. Why traditional costing tools fall short in Consumer Electronics Should Costing Should costing in consumer electronics is uniquely complex due to the density of components, diverse manufacturing processes, and unstable sourcing conditions. A typical product combines PCBAs, moulded enclosures, thermal modules, optical stacks, and batteries, each with different cost drivers and supply risks. Cost decisions are often made early, before a stable design or supplier quote exists, and every design change can disrupt the cost structure. Most costing software marketed as a should cost solution functions either as a BOM tracker or a price aggregator. A BOM tool monitors part numbers and purchase history, but cannot model tooling paths, production processes, or real overheads. A price aggregator reflects current procurement rates—not true manufacturing cost. Despite this, each is often positioned as a should cost analysis tool—leading teams to believe they are controlling cost, when in reality, they are only tracking transactions. ASI Engineering bridges this gap using xcPEP, our structured should-cost analysis software that models real production flows, sourcing logic, and part behavior to deliver accurate, part-level cost insights. BOM tools help you find the lowest purchase price, but they do not tell you what a part should cost. They cannot model processes, tooling, or overheads. At their core they are filtered spreadsheets, not costing tools. Component Price Volatility in Electronics Should Costing Component prices in electronics are highly volatile. Passive components, ICs, displays, connectors, and batteries are all affected by global demand shifts, lifecycle transitions, geopolitical changes, and supplier constraints. Even a small design update or sourcing change can lead to sudden cost variation, making static price assumptions unreliable during program execution. Intense Global Competition Consumer electronics brands today face tough competition from all sides. Large manufacturers, especially from China, design and produce everything in-house, which helps them keep prices very low. At the same time, many companies use contract manufacturers who build for multiple brands at once, bringing down costs even further. This puts pressure on every product team to reduce cost while still meeting high design and performance standards. Complex & Dense BOM Consumer electronics products include hundreds of small parts packed into very limited space. This includes multiple printed circuit boards, flex cables, brackets, screws, fasteners, and thermal materials. Each item affects layout, assembly time, and overall cost. A small change in pad layout or connector orientation can impact tooling, yield, or rework effort. These interactions are hard to track, but they play a big role in total product cost. Traditional methods like Excel sheets or BOM tools are not equipped to capture and update these changes accurately or at the speed required. High Import Dependency Many key components in consumer electronics such as displays, connectors, camera modules, and high-density integrated circuits are sourced from outside the country. The final cost is affected not just by base price but also by freight, customs duty, currency exchange, and lead time. These factors change frequently and vary by region. Cost models that do not account for region specific sourcing and landed cost variation often miss the true impact of global supply dependencies. Parts Shortage & Alternate Sourcing Shortages of key components are common in consumer electronics. A single delayed IC or connector often leads teams to find alternates at short notice. But these substitutes are rarely simple swaps. Even if the electrical function is similar, changes in footprint, height, thermal behavior, or assembly method can affect the layout, tooling, test process, or regulatory approvals. The cost impact is often indirect and not visible from the part price alone. Without a structured way to re-cost parts during alternate sourcing, teams risk introducing hidden costs that show up later in manufacturing or quality review. No Should Cost Software Connecting Engineering and Sourcing OEMs still rely on BOM spreadsheets, basic ERP exports, or procurement dashboards to manage product cost. These tools may track parts but do not explain the underlying cost structure. As a result, cost... --- > Join our Bengaluru team to build xcPEP, should costing Software powering automotive, electronics, EVs & more. Grow fast with 6-month appraisals. - Published: 2025-04-17 - Modified: 2025-08-19 - URL: https://advancedstructures.in/careers/ Join Us At Advanced Structures India, we work best with folks who are detail-oriented, can consistently execute at a high level, and enjoy thinking through problems from first principles. In our experience, when we’ve found such people, it has led to exceptional growth for them and for us. What to expect? Growth At Advanced Structures India, we run on a dynamic 6-month appraisal cycle. That means things move fast,responsibilities grow quickly, and so does compensation. If you’re someone who thrives in a high-ownership environment, this setup can lead to career growth at twice the usual pace. Product Experience Working here gives you real, hands-on product experience. If you're a software engineer, you’ll be building xcPEP and xcPROC platforms used by some of the biggest names in manufacturing. If you're from a mechanical, electrical, or electronics background, you’ll be working on EVs, drones, and tech products, getting up close with the latest subsystems and technologies. Accelerated Learning We’re deep in the weeds of cutting-edge tech across automotive, off-highway, consumer electronics, and consumer durables. Our engineers regularly dive into cost engineering studies of the newest products in these industries. We do this work with leading manufacturers, multiple times each quarter, which means you'll be learning fast, and learning from the best. View Current Openings --- > Automotive should costing by ASI Engineering with xcPEP - should cost tool, with detailed should cost models, transparent cost breakdowns & more. - Published: 2025-04-14 - Modified: 2025-07-30 - URL: https://advancedstructures.in/automotive/should-costing/ Automotive Should Costing Executed by ASI Engineering. Powered by xcPEP — should-cost analysis software for accurate, process-based cost modeling Should costing is a data-driven cost estimation approach used by automotive manufacturers to determine what a part, component, or system should cost based on its material, geometry, manufacturing process, and sourcing region. Unlike supplier quotes, which often lack transparency, should costing methodology builds cost logic from the ground up to establish internal benchmarks, uncover cost-saving opportunities, and support fact-based commercial negotiations. At ASI, automotive should costing is executed by ASI Engineering — a dedicated team focused on delivering highly accurate and transparent estimates for the automotive industry. Our experts use a combination of teardown insights, dimensional mapping, and manufacturing process modeling to replicate real production scenarios. Every estimate is built using xcPEP, our proprietary should-cost analysis software, and xcPROC, our validated cost data hub. ASI Engineering supports OEMs and Tier 1 suppliers across the full range of vehicle platforms, including passenger cars, commercial trucks, electric buses, two-wheelers, three-wheelers and hybrid systems. For every part analyzed, the team builds a manufacturing cost structure that reflects actual shop floor conditions, using ASI’s proprietary platforms, xcPEP and xcPROC, to structure and validate each model. To convert teardown data or drawings into actionable insights, ASI Engineering relies on xcPEP, our proprietary should-cost analysis software designed for real manufacturing conditions. xcPEP enables teams to create structured, part-level cost models using actual process flows, region-specific input rates, and engineering parameters—making it a powerful should cost model software. When used alongside xcPROC, our cost data hub, it becomes a complete should cost solution that supports target costing, competitor cost benchmarking, and early design decision-making. This setup ensures consistent application of a proven should costing methodology across automotive programs. By replacing fragmented spreadsheets with reliable and repeatable models, xcPEP helps OEMs and Tier 1 suppliers drive effective cost reduction initiatives in complex automotive partnerships—all within a unified, scalable should cost modelling software. Detailed Data Mapping using xcPEP To the extent of over 2 million data points mapped for a typical car makes our should costing precise and useful for decision making. Accurate should costing starts with capturing the right inputs at the right level of detail. The ASI Engineering team begins by mapping part-level data based on how each component is actually manufactured. This information is gathered through physical teardown, interpretation of 2D drawings, or direct extraction from CAD models, depending on what is available for the part. This forms the foundation for creating structured cost models inside xcPEP, our proprietary should-cost analysis software. For every part studied, the ASI Engineering team captures geometry, material specifications, and manufacturing process parameters that influence cost. The specific inputs depend on the production method. Stamped parts may require blank size, thickness, and feature count. Molded parts are defined by bounding box dimensions, wall thickness, and part weight. This data is used to generate the part’s bill of materials inside xcPEP, the should-cost analysis software, where each parameter is recorded in a structured format. From this BOM, the relevant inputs are fed into cost models built specifically for the part’s manufacturing process. These models simulate each operation using real machine data, labour inputs, and regional assumptions, resulting in a calculated cost that reflects how the part would be produced on a shop floor. In a typical vehicle program, such as a passenger car or electric four -wheeler, the ASI Engineering team maps over two million individual data points across parts and processes to support detailed cost estimation. By structuring part-level inputs in xcPEP, ASI Engineering enables teams to move away from unstructured spreadsheets and adopt a consistent, scalable should cost solution. xcPEP serves as a comprehensive should-cost analysis software, offering a unified environment to run cost simulations, build fact packs for supplier negotiations, and track cost-saving ideas. Adopted by leading automotive OEMs and Tier 1 suppliers, xcPEP supports target costing for new product development, competitor cost benchmarking and structured cost reduction studies. xcPEP reinforces a standardised should costing methodology, helping teams drive alignment across sourcing, engineering, and finance functions within complex automotive partnerships. Part Geometry Mapping ASI Engineering teams maps part details at a level of precision that goes far beyond standard BOM templates. For every component, the team records dimensional inputs, material details, supplier information, mounting method, and manufacturing category—based on teardown data, 2D drawings, or CAD data. xcPEP uses this data to determine the most suitable cost model, making it a powerful should-cost analysis software for part-level should costing. In electronic assemblies such as PCBs, each child part and subcomponent are mapped individually. Attributes such as manufacturer name, part number, quantity, board location, and mounting type are captured for every child part. For mechanical parts, the BOM includes detailed measurements such as box size, surface area, and perimeter, along with raw... --- > Reduce manufacturing cost across cars, trucks & more through should costing powered by xcPEP, software for cost reduction in automotive industry. - Published: 2025-04-14 - Modified: 2025-07-30 - URL: https://advancedstructures.in/automotive/cost-reduction-by-benchmarking-and-should-costing/ Automotive Cost Reduction Studies Reduce manufacturing cost through competitor cost benchmarking, detailed cost reduction studies, and automotive should costing using xcPEP—our advanced should cost modelling software. ASI Engineering delivers cost reduction by benchmarking your vehicle against a competitor’s—tearing both down, analyzing every cost driver, and identifying differences that lead to actionable savings ideas. Using xcPEP, our advanced should cost analysis tool, we simulate manufacturing logic step-by-step to uncover hidden cost-saving opportunities. What makes our automotive should costing methodology stand apart is the use of ASI’s proprietary should cost data—a comprehensive cost database of machines, raw materials, labor rates, and more. We do not rely on third-party estimates. This ensures every should cost model is grounded in reality. The result? A transparent, traceable, and highly accurate should cost value that explains how every figure is derived. This level of clarity helps your team move beyond surface-level cost assumptions to uncover deep, engineering-driven cost reduction opportunities. 1. Teardown benchmarking Of Customer's & Competitor's Vehicles 2. Should Costing Of Customer's & Competitor's Vehicles 3. Cost Reduction Idea Generation By analyzing cost gaps between customer's and competitor's vehicles. Challenges in Cost Reduction in Automotive Industry Too many opinions, too little data Inaccurate should-costing When should costing is based on assumptions rather than real manufacturing logic, the output lacks credibility and often fails to hold up in supplier negotiations. To drive meaningful results, teams need accurate should cost modelling software that reflects actual production processes. Scattered data across teams Different teams often use separate Excel files or isolated tools for should costing, leading to duplication, inconsistency, and confusion. Without a unified should costing software used across the organization, it’s impossible to maintain a single, aligned view of cost drivers. Limited process-level breakdown Most teams rely on outdated or legacy should cost analysis software that doesn’t break down costs at the operation level. Without a clear view of how each manufacturing step contributes to the final cost, engineering teams struggle to identify true savings potential. Poor idea tracking across projects Manual tools like Excel don’t support ongoing tracking of savings ideas. A proper cost analysis platform ensures follow-through, collaboration, and long-term retention of cost reduction opportunities. xcPEP Should Cost Tool Turns Raw Teardown Data Into Repeatable Savings xcPEP, our cloud native should costing software ingests the complete teardown of your vehicle and a direct competitor, aligns every geometry point, material grade, machine setting, labour input, and logistics factor, then calculates the cost gap part by part. Its analytics engine pinpoints where you overspend, identifies the technical or commercial driver, and ranks every saving by impact and ease of execution. Engineering and purchasing teams receive a clear action list with quantified benefit and implementation guidance, all inside one shared platform. Each study starts with a structured teardown of both vehicles, and xcPEP converts that raw benchmark data into a living model that keeps your targets ahead of the market. Superior Data Mapping in xcPEP xcPEP, our should costing software brings structure, speed, and repeatability to cost reduction by automating the capture of geometry, material, and process-related inputs. ASI Engineering uses in-house systems to extract all key dimensions and features that affect manufacturing cost. PCB assemblies are scanned and classified using AI, physical parts are measured for bounding box dimensions and projected area—all without manual input. The captured data flows directly into xcPEP, where it is linked to the correct BOM line and mapped to process logic. This allows teams to compare each part against a benchmark with precision and identify where cost gaps are driven by design, material, or manufacturing choices. Part Measurement Data 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. Accurate Raw Material Identification 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. Detailed Manufacturing Process Calculation For each part, ASI Engineering models the real manufacturing route including stamping, molding,... --- > Set up your in-house should costing lab with ASI. We deploy xcPEP, train your team, migrate cost models, and hand over a fully operational lab. - Published: 2025-04-14 - Modified: 2025-08-19 - URL: https://advancedstructures.in/xcpep-should-cost-analysis-software/lab-build-operate-transfer/ Should Costing Lab Build, Operate & Transfer In an era of cost-conscious innovation, Should Costing is no longer a nice-to-have, it’s essential. But building the internal capability to drive cost-informed design and sourcing decisions can take years. That’s where we come in. ASI Engineering's Build–Operate–Transfer (BOT) model helps manufacturing companies establish a fully functional Should Costing lab; faster, better, and with guaranteed outcomes. Build We start with setting up the core infrastructure, processes, and tools required for an effective costing function. Identify target categories (mechanical, electrical, plastic, etc. )Define lab KPIs and operational modelsConfigure our cloud-based xcPEP® Should Costing software to suit your product familiesStaff the lab with ASI-trained engineersCreate SOPs and workflows. Operate During this phase, ASI runs the cost lab as a managed service to ensure outcomes and build institutional maturity. Deliver end-to-end Should Costing reports across identified partsEmbed in sourcing, design, and cost reduction workflowsRun value engineering and cost teardown workshopsEstablish linkages with vendor negotiation teamsTrain internal engineers alongside delivery Transfer Once the lab has proven its capability and your team is ready, we ensure a seamless transfer. Transition lab operations to your in-house teamInstitutionalize documentation, playbooks, and audit methods. Provide long-term digital access to historical reports via xcPEP. Stay available as a scaling or escalation partner. Deployment & Configuration Included in our Build - Operate - Transfer services are all activities required to configure and deploy xcPEP. Read More --- > Deploy xcPEP with ASI: we configure it to your needs, create cost models, migrate data, and train your team to perform should costing using xcPEP. - Published: 2025-04-09 - Modified: 2025-08-19 - URL: https://advancedstructures.in/xcpep-should-cost-analysis-software/deployment-training/ xcPEP Deployment Handled end to end by ASI Engineering We partner with your cost engineering, sourcing teams and other stakeholders to deliver a robust and effective should costing rollout. Requirement Mapping & Planning Our approach begins with understanding your organization’s current costing maturity and aligning xcPEP’s capabilities to your goals. Activities at this stage are: Step 1 Stakeholder workshops to define the business case for should costing. Step 2 Identification of pilot categories or commodity families. Step 3 Integration planning with existing PLM, ERP, and design workflows. Step 4 Definition of target outcomes. Data Discovery, Cleansing & Migration Effective should costing requires clean, structured, and traceable data. ASI Engineering supports every aspect of data readiness. This ensures a clean and scalable data foundation for should costing analytics. Activities at this stage are: Step 1 Cleansing of BOMs, drawings, and cost records. Step 2 Mapping part attributes to xcPEP’s data model. Step 3 Migration of part master data, historical costs, and supplier inputs. Step 4 Upload and verification inside xcPEP. BOM & Cost Model Configuration Every manufacturer has a unique way of organizing products into product lines, each with its own BOM structure, grouping logic, and nomenclature. Additionally, variations in regions, production volumes, quality standards, and internal cost models require tailored adjustments. ASI Engineering handles all of this during the configuration stage ensuring xcPEP is fully aligned with each customer’s specific product architecture, operating norms, and cost modeling requirements. Database Configuration ASI Engineering creates and configures various types of database for effective use of xcPEP Raw Material Database Most manufacturers have a database of raw materials used in their built-to-print parts category. Since xcPEP covers all parts for costing, ASI Engineering works with customers in creating raw material database for built-to-spec and proprietary parts as well. Machine Hour Rate Database Every large manufacturing company has a diverse supply chain. ASI Engineering maps the regions, popular machines in each category being used in those specific regions and corresponding costs of purchase, operation, maintenance and power etc. This ensures xcPEP customers are always working with the most realistic input parameters for costing. Labour Hour Rate Database Large manufacturing companies operate across regions with varying labor dynamics. ASI Engineering captures region-wise labor classifications, standard job roles, prevailing wage rates, and associated overheads like statutory contributions, training, and shift differentials. This enables xcPEP users to cost with regionally accurate labor hour rates, ensuring estimates reflect real-world conditions. Bought Out Parts Database Manufacturing companies often use a wide range of standard parts such as resistors, capacitors, ICs, fasteners, bearings, seals, and bushings within their products. ASI Engineering builds a customized database for each customer, mapping the exact standard parts involved in both in-house manufacturing and externally sourced assemblies. Forex In global supply chains, forex conversion and hedging plays a significant role. We map your global supply chain and create a database of relevant currencies so costing outputs are always aligned with real work scenario. System Deployment & Integration Support Whether you’re running SAP, Oracle, Teamcenter, or a custom ERP, our team can integrate xcPEP with your enterprise systems securely. We support API-based integrations with ERP, PLM and other tools. SSO, access control, and user management setup. Testing environments and change control mechanisms. Training Our hands-on training programs empower cross-functional teams to become confident users of xcPEP and skilled practitioners of should costing. We provide tailored training and support for all stakeholders, aligned with their specific roles and use cases within xcPEP. Training can be delivered on-site, online, or in a hybrid format to suit customer needs. Ongoing Support We support your internal teams in an ongoing manner to ensure xcPEP is utilized in a manner most suitable to your business requirements. Towards this end we provide the following services: RM, LHR, MHR, BOP database research and update service. Development of new cost models for new commodities your team encounters. Costing services to remotely offload work when you have a surge in requirements. --- > Explore xcPROC —a database with material, machine, labor, and process costdata for accurate, region-specific should-costing - Published: 2025-04-07 - Modified: 2025-09-10 - URL: https://advancedstructures.in/xcproc-costdata/ xcPROC Should CostData CostData for Should Costing xcPROC is a structured database that supports xcPEP users with input data required for costing. It is curated by our own data research team and updated quarterly so xcPEP users have access to realistic and current input data. xcPROC is a data & insights platform. xcPROC is a data and insights platform built around structured databases used for cost estimation and supplier evaluation. It includes seven core datasets: raw materials, machines, operations, labour, standard parts, suppliers, and currency. These datasets form the foundation of all should-cost models in xcPEP, enabling accurate cost estimation without relying on generic averages or static reference tables. Unlike fixed-format databases, xcPROC is actively maintained by ASI’s internal research team and expands continuously. Updates are driven by real project requirements, and custom datasets are developed when clients need support for specific parts, processes, or geographies. This makes xcPROC a dynamic, engineering-led alternative to static cost datasets provided by conventional platforms. xcPROC is a vendor discovery and evaluation platform. xcPROC has supplier profiles that show manufacturing capability, business information, and financial data in a clear structured format. Known and potential parts are mapped for each supplier based on production history and process-level analysis. Profiles also include customer associations, certifications, and downloadable product catalogues. Business sections cover revenue, plant locations, director details, and open financial charges—supporting both technical fitment and risk evaluation. This combination of data supports supplier shortlisting, risk evaluation, and sourcing decisions—all within the same system. The data is curated and maintained by ASI’s internal research team. xcPROC is a marketplace. xcPROC is a part-level marketplace that supports the evaluation and procurement of mechanical and electrical components. Each listed part includes detailed technical specifications, price–quantity data, and ordering options linked to a known manufacturer. Potential manufacturers are also mapped through capability analysis based on machines, processes, and other production parameters. This allows sourcing teams to identify feasible alternatives without restarting supplier evaluation. All orders placed through the platform are fulfilled by the ASI team. The database is regularly updated, with new listings added by ASI data research team. Explore Data on xcPROC Visit xcPROC. com ASI Data Research Team Our war on generic data The ASI Data Research Team is responsible for developing, maintaining, and expanding the datasets available in xcPROC. This team ensures that the data is validated, structured, and aligned with the practical needs of engineering and sourcing functions. All datasets are updated on a regular basis, and new ones are built whenever project requirements go beyond the existing scope. Rather than relying on broad industry averages, xcPROC develops data specific to how each part is actually manufactured and sourced. This approach stands in contrast to conventional cost data platforms that rely on fixed-format libraries and broad averages. xcPROC is built to replace generic cost datasets with application-specific information that reflects how real parts are made, sourced, and evaluated. The database evolves continuously, supporting part-level cost estimation and supplier evaluation without the limitations of static references. What is a generic database and why do we dislike it so much? Generic datasets rely on assumptions and broad averages that ignore how parts are actually made. They often simplify cost inputs to fit fixed templates, which leads to estimates that do not match real manufacturing conditions. In cost engineering, even small differences can change the outcome. When the input data lacks specificity, the costing becomes guesswork. This is why ASI avoids generic datasets and built xcPROC as a structured database so that cost models reflect actual manufacturing conditions, not assumptions. What is ASI's approach? ASI’s approach is to build and maintain its own centralized data platform—xcPROC—to support cost estimation and supplier evaluation. Instead of relying on third-party generic sources, ASI creates structured datasets in-house, tailored to reflect actual manufacturing conditions. When existing data does not cover a specific part, process, or geography, a new dataset is developed from scratch. ASI’s approach is to build and maintain its own centralized data platform—xcPROC—to support cost estimation and supplier evaluation. Instead of relying on third-party generic sources, ASI creates structured datasets in-house, tailored to reflect actual manufacturing conditions. When existing data does not cover a specific part, process, or geography, a new dataset is developed from scratch. How xcPROC powers xcPEP’s should-costing models ? xcPROC serves as the data backbone for xcPEP, ASI’s should-costing platform. Every cost model built in xcPEP draws its inputs from xcPROC' s structured datasets—covering raw materials, machines, operations, labour, standard parts, and suppliers. This integration ensures that cost estimates reflect real production parameters rather than assumptions or static references. When xcPEP is deployed in new projects, xcPROC evolves alongside it—new data is added, existing values are validated, and client-specific requirements are incorporated. Database Components Vast Library and Customer Specific Customizations xcPROC houses a growing set of structured... --- > xcPEP is a purpose-built should cost analysis software with real-time, editable cost models designed for engineering, sourcing and finance teams. - Published: 2025-04-07 - Modified: 2025-08-21 - URL: https://advancedstructures.in/xcpep-should-cost-analysis-software/ xcPEP Should Cost Analysis Software Should Costing You Can Defend, Cost Models You Can Trust. xcPEP Should Cost Analysis Software What is xcPEP? xcPEP is a next-generation Should Costing platform built to solve real-world costing challenges. It enables teams to estimate part costs using manufacturing logic, regional rates, and technical parameters without relying on static averages or black-box assumptions. xcPEP is industry-agnostic, role-adaptive, and supports both individual costing tasks and large-scale digital transformation of cost functions. With full transparency into calculations and inputs, it helps teams defend decisions, align cross-functionally, and negotiate with confidence. 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TappingMachine TappingBlind Hole TappingThread FormingTurningExternal TurningFacing on LatheGrooving & PartingThread TurningMillingFace MillingSlot MillingProfile MillingEnd MillingThreadingSingle-Point Thread CuttingRolling DiesThread MillingFacingLathe FacingPlunge FacingFacing in Chuck WorkBroachingInternal Keyway BroachingExternal Surface BroachingRotary BroachingGrindingSurface GrindingCylindrical GrindingCenterless GrindingTool GrindingBoringLine BoringJig BoringHorizontal BoringNotchingTube NotchingSheet Metal Corner NotchingAngle NotchingLaser CuttingFiber LaserCO₂ LaserPulse Laser for MicrocuttingHoningManual HoningVertical HoningPlateau Honing (Automotive)Gear HobbingSpur Gear HobbingHelical Gear HobbingSpline Cutting via HobbingGear ShapingInternal Gear ShapingExternal Gear ShapingTiming Gear ShapingGear ShavingRadial Infeed ShavingDiagonal ShavingUnderpass MethodGear GrindingProfile GrindingGenerating GrindingForm GrindingShot BlastingSteel Grit BlastingWheel Blast SystemsShot Blast CleaningShot PeeningAir Blast PeeningGravity PeeningSaturation PeeningSand BlastingSuction SandblastingPressure BlastingAbrasive Media SelectionLappingFlat LappingCylindrical LappingPolishing and Final Finishing Welding & Joining MIG / MAG WeldingCarbon Steel MIGStainless MAGPulse MIG for AluminumTIG WeldingManual TIGOrbital TIGThin Section WeldingSpot WeldingProjection Spot WeldingCross Wire WeldingResistance Spot WeldFriction Stir WeldingAluminum Profile JoiningTool Steel Weld HeadAutomated Linear FSWLaser WeldingKeyhole WeldingConduction WeldingFine Micro-WeldsUltrasonic WeldingPlastic Ultrasonic WeldingWire SplicingBattery Tab WeldingRiveting / ClinchingSolid RivetingBlind... --- > Automotive should costing done by ASI Engineering using xcPEP, our should cost model software for target costing, benchmarking & cost reduction. - Published: 2025-04-05 - Modified: 2025-08-19 - URL: https://advancedstructures.in/automotive/ Automotive ASI Engineering is the in-house services team at Advanced Structures India, dedicated to supporting users of our SaaS platforms : xcPEP, our should cost analysis software used extensively for automotive should costing and xcPROC, Should Cost Data Hub. We facilitate smooth onboarding to xcPEP and, when needed, support the setup of in-house cost labs at customer locations. We also undertake custom projects in target costing, cost benchmarking, and cost reduction idea generation. 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. The following are project-based services we offer to customers, built on and delivered through our xcPEP and xcPROC platforms. Should Costing We conduct should costing on your or competitor vehicles, using drawings or teardowns of physical parts for analysis. Cost Reduction Studies We compare your and competitors' vehicles part by part, across cost drivers, to generate impactful cost reduction ideas. Onboarding We tailor xcPEP to your products, suppliers, and locations, and build customer raw material, MHR, and LHR datasets. Cost Lab B-O-T We set up a cost lab in your organization, develops SOPs, train your team through live projects and deliver a functional cost lab. Deployment and Cost Lab Build-Operate-Transfer are services through which the ASI Engineering team ensures xcPEP, our automotive should costing software is properly configured and effectively utilized for automotive should costing and related applications. How are we different? We build cost engineering technology. Our core products, xcPEP for should cost modelling and xcPROC for cost data, form a powerful ecosystem supported by engineering services that speed customer adoption. While we may resemble consulting or benchmarking firms, the similarity is only superficial; our strength lies in the technology we create. ASI vs. Management Consultants vs. Benchmarking Companies Approaches to Automotive Cost Engineering & Value Optimization ASI – Engineering-Led Cost Transformation Management Consultants Benchmarking Companies 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: xcPEP – part-level costing & simulation xcPROC – procurement intelligence Enables rapid, high-accuracy costing and targeted idea generation. 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. Our Core Objective Engineering Led Cost Transformation Of Automotive OEMs and Tier 1 Suppliers Challenge ASI Solution Value Key Challenges Opaque cost structures for high value parts Volatile input costs Scattered data across teams Limited visibility into drivers Our Framework Part-level costing using xcPEP Supplier cost mapping via xcPROC Should Costing of each and every part Unified data layer for decision-making Business Impact EBITDA uplift Faster time-to-insight Improved exit multiples Sustained competitive edge Core Technology Platforms xcPROC Procurement Intelligence xcPEP Costing Engine Precise Should Costing xcPEP Idea Module Automated Design & Commercial Idea Generation Build - Operate - Transfer Engagement Model Phase 1: Build Detailed Should-Costing Foundation Phase 2: Operate Idea Generation & Implementation Phase 3: Transfer Cost Engineering Function Handover Data mapping from drawings and teardown Teardown analysis of proprietary and competitor products Alignment of cost models with company's reality Development of raw material, LHR, MHR databases aligned to company’s products and supply chain Supplier & route mapping Should costing of everything the company makes and buys Engineering idea generation: design / material / supplier / process / packaging changes Engineering idea implementation Commercial idea generation: negotiation gaps, alternate suppliers, import/export data Commercial idea implementation Cost Engineering Function is created inside the company Full handover of platform and processes Training, documentation, and continued support... --- > Learn about Advanced Structures India, creators of xcPEP should-cost software and xcPROC cost data, built for real world, scalable should costing. - Published: 2025-04-05 - Modified: 2025-09-06 - URL: https://advancedstructures.in/about-advanced-structures-india/ About Us We are Advanced Structures India. Over the past decade, we’ve built Cost Engineering SaaS - xcPEP Should Costing Software & xcPROC Should Cost Database, not by tweaking legacy ideas, but by rethinking the discipline from first principles. Today, our products define new industry benchmarks and are used by global and Indian leaders across automotive, consumer electronics, appliances, and off-highway sectors - often leading to the creation of dedicated internal functions around them. Since 2020, we’ve focused exclusively on developing and deploying our cost engineering SaaS built from first principles and continuously refined through direct, real-time feedback from our customers. Adoption of our technology Cost engineering is a sensitive and complex domain, made more challenging by global supply chains and the need for precise, region-specific process data. Most companies treat it as a core internal capability, rarely opening it to external teams. Gaining their trust requires exceptional technical depth, discretion, and integrity. We’ve earned that trust, one customer at a time, across industries and geographies. The strength of our technology and support has led several companies to establish internal cost labs built around xcPEP and supported by ASI. This trust is rooted in: Exceptionally better results than legacy software. Compliance with enterprise level information security from our early days. Track record of one decade. Timeline This is the year wise summary of our journey so far. Progress in years 2025 xcPEP SaaS is now live at top-tier firms across automotive, home appliances, and consumer electronics sectors. A growing number of services customers are transitioning to xcPEP’s SaaS model. 2024 Launched xcPROC to address data gaps in raw material, machine, and labor inputs extending our product ecosystem beyond xcPEP. 2023 xcPEP took center stage in our offerings, while traditional services were scaled down to prioritize product-led growth. 2022 Became the dominant player in EV Should Costing serving 3 out of the top 5 EV makers across categories. 2021 Enhanced xcPEP capabilities through advanced Should Costing algorithms. Started working with home appliance, consumer electronics and off highway vehicle manufacturers. 2020 Strategic pivot: discontinued non-core services to focus entirely on xcPEP and Should Costing solutions. 2014-2020 We offered a wide spectrum of engineering services covering design, simulation, testing, teardown benchmarking, performance benchmarking to automotive customers. Should Costing was a part of our offerings during this period and ASI Datalab (now xcPEP) was an internal tool. xcPEP Should Cost Analysis Software What is xcPEP? xcPEP is a software platform used by companies to estimate, analyze, and optimize the manufacturing cost of parts and products. Who uses xcPEP? Internal teams such as engineers, sourcing, and cost analysts within the company. Key Applications of xcPEP- Should Costing of products and product portfolio wide updates of input costs. - Competitor product benchmarking and should costing. - Cost driver analysis and cost reduction idea generation. Data Ownership in xcPEPAll data inside xcPEP is created and owned by the company using it. It is confidential and used only for their internal purposes. ConfidentialityEach company's data in xcPEP is secure, private, and not shared with any other organization. Interaction with xcPROCxcPEP operates independently for internal Should Costing and cost analysis. xcPROC Procurement & Cost Database Platform What is xcPROC? xcPROC is an external-facing marketplace and vendor discovery platform where suppliers showcase their parts, materials, and manufacturing services. It also serves as a cost database maintaining verified rates for machine hour (MHR), labour hour (LHR), tooling, raw materials, and other databases required for real world should costing. Who uses xcPROC? - Suppliers use it to showcase their offerings and connect with buyers. - Sourcing and procurement teams use it to discover and evaluate qualified suppliers. - Cost engineers and commodity managers use it as a trusted cost database for should costing. Key Applications of xcPROC– Discover and evaluate suppliers by category, capability, and region– Run vendor pre-qualification checks using GST, financial, and compliance data– Access verified cost databases including MHR, LHR, material prices, and tooling rates– Use as a procurement platform to connect with manufacturers and service providers– Power should-costing models with real-world cost data inside xcPEPData Ownership in xcPROCAll data inside xcPROC is sourced, researched, and owned by Advanced Structures India (ASI). ConfidentialityxcPROC showcases supplier information publicly for registered buyers, but the underlying data is maintained and controlled by ASI. Interaction with xcPEPOne of the use cases of xcPROC cost data is to provide updated and high-quality raw material rates, suppliers names and their capabilities to xcPEP users. Our People Vaibhav B Kumar Founder & CEO Pratik Kumar Shukla Co-Founder & CTO Alexander K A Head - Engineering Shivam Tiwari Head - Operations Our Teams Software Development Develops and maintains our products. Solution Architecture Configures xcPEP for individual customer's needs. Data Research Conducts primary and secondary research for cost data. ASI Engineering Custom should costing projects, Cost Lab setup.... --- > Advanced Structures India delivers accurate, scalable Should Costing through the xcPEP® SaaS platform and the xcPROC® cost data platform. - Published: 2021-10-06 - Modified: 2025-09-08 - URL: https://advancedstructures.in/ Should Costing Revolution xcPEP delivers real-world accurate, transparent & defensible should cost analysis of mechanical, electrical & electronics components from drawings or physical parts. About Us xcPEP - Cost Engineering SaaS xcPROC - Data & Insights xcPEP Our Cost Engineering SaaS xcPROC Our Data & Insights Hub Engineering Our In House Services Team xcPEP ecosystem combines advanced costing tools with up-to-date data for precise cost. xcPEP SaaS for precision costing, real-world decisions. xcPEP is a purpose-built platform for cost engineering and procurement teams, designed to deliver precise, actionable cost insights for real-world decision-making; unlike legacy tools that were built primarily for designers to generate rough estimates during early development stages. xcPROC Verified cost data for should cost models. xcPROC is a platform for supplier discovery, gathering verified data on material rates, capabilities, and certifications. Managed by Advanced Structures India, it provides real-world insights for informed decision-making and integration with xcPEP. xcPEP ecosystem combines advanced costing tools with up-to-date data for precise cost. xcPEP SaaS for precision costing, real-world decisions. xcPEP is a purpose-built platform for cost engineering and procurement teams, designed to deliver precise, actionable cost insights for real-world decision-making—unlike legacy tools that were built primarily for designers to generate rough estimates during early development stages. xcPROC Specific, real and specifically researched input data. xcPROC is a platform for supplier discovery, gathering verified data on material rates, capabilities, and certifications. Managed by Advanced Structures India, it provides real-world insights for informed decision-making and integration with xcPEP. xcPEP Ecosystem More than just software. xcPEP isn't just a tool. It’s an ecosystem that includes best-in-class data, custom research on new materials and components, and on-demand model development tailored to your product categories and supplier base. xcPEP is designed for cost engineering and sourcing teams. Region-specific material, labour, and supplier data from xcPROC insights. Constant support from ASI Engineering team. Proven at scale with global manufacturers with diverse supply chains. View more Getting Started with xcPEP - here's how most of our customers have done it. Configuration and Alignment Our in-house team analyzes your products, supply chain, materials, and other key details to configure your xcPEP deployment so it aligns seamlessly with your real-world operations. Database Updates Our Data Research team delivers a tailored database of material, labor, and machine rates, specific to your products and locations, kept fresh with regular updates for consistently reliable input data. Ongoing Support Whenever you introduce a new commodity, manufacturing process, product category, or sourcing location, our in-house engineering team gets you up to speed with minimal lead time. 'ASI Engineering' is our in-house services team. It works with customers on costing projects and turnkey cost lab setup. Automotive Highly engineered parts and global sourcing need accurate, fast cost modeling. Precise costing for better cost control. Off Highway Low volumes and diverse part types demand flexible costing logic. Specialized cost models for low volume production. Home Appliances Frequent design changes and cost-sensitive markets require agile costing. Quicker cost rollups and price validation. Consumer Electronics Complex electronics BOMs and assembly steps make traditional costing unreliable. Improved visibility into EMS and board-level cost drivers. 'ASI Engineering' is our in-house services team. It works with customers on costing projects and turnkey cost lab setup. Automotive Highly engineered parts and global sourcing need accurate, fast cost modeling. Better alignment with target costs and supplier quotes. Off Highway Low volumes and diverse part types demand flexible costing logic. Optimize sourcing and custom-build decisions. Home Appliances Frequent design changes and cost-sensitive markets require agile costing. Quicker cost rollups and price validation. Consumer Electronics Complex electronics BOMs and assembly steps make traditional costing unreliable. Improved visibility into EMS and board-level cost drivers. Why are global manufacturers switching to xcPEP? Real-World Process Accuracy Legacy tools use generic logic; xcPEP reflects real, region and industry specific manufacturing practices for higher accuracy. Verified Input Data Instead of relying on outdated generic libraries, xcPEP provides up-to-date, validated material and labor data. High-Speed Performance Older systems are slow. xcPEP is cloud-native and built for speed, even with complex assemblies. Shorter Learning Curve Legacy interfaces are clunky. xcPEP is intuitive and easy to adopt across teams. Comprehensive Process Coverage xcPEP includes wide-ranging processes which cover every single type of part used in automotive, off highway, home appliances and consumer electronics. xcPEP does costing of own as well as bought-out parts. Effortless Onboarding & Customization No need for consultants. xcPEP is modular and easy to tailor to your specific operations. ASI Engineering works to hand over a functional xcPEP deployment for each customer. Born in Cloud xcPEP is built for the cloud, ensuring fast access, zero downtime, and smooth automatic updates. Engineering Support That Scales xcPEP users get expert support from 'ASI Engineering' for model development, custom processes, and new categories. One-Third the Cost of Ownership xcPEP’s cloud-native design and modern... --- --- ## Posts > This study reveals a full refrigerator should costing & teardown analysis, BOM, cost drivers, and sourcing insights for Direct Cool single door fridges. - Published: 2025-09-22 - Modified: 2025-09-23 - URL: https://advancedstructures.in/teardown-should-cost-analysis-bom-direct-cool-refrigerator/ - Categories: Home Appliances Product Studies The teardown of Haier’s 190L Direct Cool refrigerator reveals major cost drivers like the compressor, sheet metal, and foam moulding. While packaging adds bulk, sourcing efficiency for lightweight yet costly parts like wiring and PCBs remains crucial for cost optimization. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publication. Introduction to Refrigerator Should Costing & Teardown Study Refrigerators are among the most widely produced and cost-sensitive appliances, making cost transparency essential for manufacturers and procurement teams worldwide. This study presents a teardown and refrigerator should-costing analysis of a Haier Direct Cool 190 Ltr (2-Star) single-door model, carried out by ASI Engineering with xcPEP to evaluate its design, materials, and manufacturing economics. This teardown is conducted from a functional and component-level perspective to estimate the Bill of Materials (BOM) and uncover the cost distribution across key subsystems. Features & Specifications of Direct Cool Refrigerator Below is a detailed breakdown of its design, performance, energy usage, and functionalspecifications: Direct Cool Technology The refrigerator uses Direct Cool technology for its cooling operation. It relies on natural convection, meaning there is no fan to circulate air. This results in lower energy consumption and minimal noise during operation. The defrosting process is manual and can be activated using a push-Button, requiring periodic user intervention to remove frost buildup. Refrigerator Compressor The EKZ60K is a fixed-speed reciprocating compressor operating on a 220–240V, 50 Hz single-phase supply. It uses R600a(Isobutane) refrigerant and has a Locked Rotor Amps (LRA) rating of 7. 1A. Its approximate cooling capacity is 600–700 BTU/h, ideal for small direct cool refrigerators. Refrigerator Capacity The refrigerator has a total capacity of 190 litres, organized into several compartments. It features a 14-litre freezer with Diamond Edge Technology for efficient ice formation and an 11. 5-litre vegetable case covered with a lid measuring 415 x 235 mm for moisture retention. The main chamber includes two toughened glass shelves, each with a surface area of approximately 145,000 mm², and four door shelves for bottles and condiments. Additionally, it has a chiller tray with a maximum area of 428 x 338 mm. Defrosted ice water collector The refrigerator also includes a defrost water collection system to prevent water accumulation inside the cabinet. When manual defrosting is performed, the melted ice flows down to the chiller tray, passes through a drain funnel, and is finally collected in a 3-litre water collector located at the rear. Working of Refrigerator: Cooling Cycle Explained 1. Power Supply Power is supplied through the plug connected to the AC mains, where the black wire is live, red is neutral, and green/yellow is earth. 2. Door Switch Operation If the refrigerator door is open, the door switch closes, turning on the lamp to illuminate the compartment. If the door is closed, the door switch opens and the lamp turns off. 3. Thermostat Operation The thermostat monitors the internal temperature and remains open when cooling is not needed, preventing power from reaching the compressor. 4. Relay and Start Capacitor When the internal temperature rises above the set point, the thermostat closes, allowing power to flow to the compressor circuit. The relay is energized and temporarily connects the start winding and capacitor to assist in starting the compressor motor. The start capacitor provides a phase shift, helping the compressor motor generate enough torque to start. Once the motor reaches sufficient speed, the relay automatically disconnects the start winding, and the compressor continues to run on the main winding. 5. Refrigerant Compression The compressor compresses low-pressure refrigerant gas from the evaporator into high-pressure, high-temperature gas. 6. Condensation in Condenser Coils This hot gas flows through the condenser coils on the outside back of the fridge, where it releases heat to the surrounding air and condenses into a liquid. 7. Pressure Drop via Capillary Tube The liquid refrigerant passes through the capillary tube, where its pressure and temperature drop significantly. 8. Evaporation in Evaporator Coil The cold, low-pressure refrigerant enters the evaporator coil in the freezer compartment and evaporates by absorbing heat from the inside. This evaporation cools the freezer and refrigerator compartments and forms frost on the evaporator surface. 9. Refrigerant Returns to Compressor The resulting low-pressure gas returns to the compressor to begin the cycle again. 10. Cooling Cycle Control Once the desired temperature is reached, the thermostat opens, cutting power to the compressor and stopping the cooling. This cooling cycle repeats automatically as the thermostat continuously monitors the internal temperature. Refrigerator Compressor: Working Principle & Cycle 1. Power Supply Activated When the fridge temperature rises above the set point, the thermostat closes, allowing 220–240V AC to power the single-phase motor inside the compressor. 2. Rotor Starts Rotating The stator generates a rotating magnetic field that spins the rotor (Ø 51. 5 mm), initiating the compressor cycle. 3. Crankshaft Driven by Rotor The rotor motion drives the crankshaft (121. 5 mm long), converting... --- > Refrigerator compressor teardown and should costing with BOM details, component weights, cost drivers, and benchmarking analysis - Published: 2025-09-15 - Modified: 2025-09-17 - URL: https://advancedstructures.in/refrigerator-compressor-should-costing-benchmarking/ - Categories: Home Appliances Product Studies Discover a detailed teardown and should-cost analysis of a refrigerator compressor used in a 190L single-door model. This study explores BOM insights, cost drivers like motor assemblies and copper windings, and benchmarks a ₹2077 per unit should-cost. Learn how OEMs can optimize costs, localize suppliers, and design smarter, energy-efficient appliances for the Indian market. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Introduction: Decoding Refrigerator Compressor Costs through Should Costing & Component Benchmarking The home appliance industry in India is witnessing steady growth, driven by increasing consumer demand for energy-efficient and affordable refrigeration solutions. As manufacturersfocus on improving performance and adhering to energy ratings, understanding the cost dynamics of key components—especially the refrigerator compressor—becomes crucial for pricing, sourcing, and design decisions. This analysis dives deep into the teardown and should-costing evaluation of a typical single-door refrigerator compressor, used in a popular 190L, 2-star rated model. We explore the Bill of Materials (BOM) in detail and map out the cost contribution of compressor subcomponents, such as the rotor, stator, enclosure, and refrigerant-related fittings. This comprehensive study aims to deliver insights into compressor cost optimization, energy efficiency enhancements, and supplier benchmarking to help OEMs and component manufacturers make informed engineering and procurement decisions. Refrigerator Compressor Specifications: A Foundation for Cost Analysis Understanding component-level specifications is essential for accurate cost estimations and engineering analysis. In this case, we examine the refrigerator compressor used in the Haier 190 L, 2-Star, Direct Cool Single Door Refrigerator (Model: HRD-2102BNS-P). As a commonly used appliance in the Indian household segment, this model provides a relevant basis for compressor should-cost evaluation. Parameter Details Compressor Type Reciprocating (Hermetic Sealed) Cooling Capacity ~165–180 Watts (approx. 550–615 BTU/hr) Refrigerant Type R600a (Isobutane) Rated Voltage 230V AC, 50Hz Starting Method Capacitor Start with Relay-Controlled Start Winding Operating Current ~0. 6–0. 8 Amps Power Input ~90–120 Watts Displacement Volume 5. 2 cm³ Energy Efficiency Compliant with 2-Star BEE energy rating Noise Level ≤ 42 dB (during standard operation) Compressor Weight 6. 38 kg Compressor Housing Steel shell with vibration isolators Lubricant Type Polyolester (POE) oil Application Designed for small-capacity, single-door refrigerators Compressor Component Architecture: Deconstructing for Cost Insights The refrigerator compressor may appear compact, but it comprises several intricately engineered components working in unison to deliver efficient refrigerant compression. Adetailed teardown of the compressor helps us understand assembly complexity, component interdependence, and key cost-driving elements—critical to precise should costing and appliance benchmarking. This compressor component breakdown allows us to identify material choices, manufacturing intricacies, and integration challenges, offering a structured view into refrigerator compressor cost drivers. Below are the primary elements analysed during teardown: Electric Motor Assembly: Powering the Compression Cycle At the heart of the compressor lies the electric motor, which converts electrical energy into mechanical motion. It includes copper windings, stator laminations, and a dynamically balanced rotor shaft. These subcomponents contribute significantly to the electromagnetic performance and cost structure of the compressor. Motor StatorWeight: 1984 gMaterial: Copper and steel(CRNGO)Function: Generates the magnetic field to drive therotor. Stator CoreWeight: 17 g | Quantity: 78 nosMaterial: Electrical Steel (CRNGO)Function: Provides a magnetic path and supports stator windings. Motor RotorWeight: 594 gMaterial: Aluminium & SteelFunction: Spins inside the stator to create mechanical energy Crankshaft: Translating Motion The steel crankshaft converts the rotary action of the motor into the reciprocating motion required to drive the piston. Precision machining and material selection here are essential for durability and low friction losses, directly influencing the mechanical efficiency and part cost. CrankshaftWeight: 118 gMaterial: SAE 4140Function: Drives the piston in the cylinder block Piston and Cylinder Assembly: Compression Core This subsystem is responsible for compressing the refrigerant gas. Made of hardened steel or cast iron, the piston-cylinder pair is subject to high-pressure loads and must maintain tight tolerances. Their weight and finish contribute measurably to the compression efficiency and material cost. Connecting RodWeight: 22 gMaterial: Fe-Cu powder (Iron-copper powder)Commodity: Powder metallurgy. Function: Transfers crankshaft motion to the piston. PistonWeight: 20 gMaterial: Fe-Cu powder (Iron-copper powder)Commodity: Powder metallurgyFunction: Compresses refrigerant gas. Piston Cylinder HousingWeight: 904 gMaterial: cast ironCommodity: Sand CastingFunction: Encloses piston; forms chamber for compression. Valve Plate & Reed Valves: Gas Flow Control A critical component set includes reed valves made of stainless steel and the valve plate, which together manage refrigerant intake and discharge. These thin precision-formed parts ensure unidirectional gas flow and must withstand repeated thermal cycles without fatigue, key contributors to functional performance and cost. Valve PlateWeight: 34 gMaterial: Fe-Cu powder (Iron-copper powder)Commodity: Powder metallurgyFunction: Holds and supports suction and discharge reeds. Valve Suction ReedWeight: 2 gMaterial: SteelFunction: Opens to allow refrigerant into cylinder. Valve Discharge ReedWeight: 0. 15 gMaterial: SteelFunction: Opens to release compressed refrigerant gas. Compressor Shell: Structural Housing The outer casing, typically deep-drawn or welded steel, acts as a pressure vessel and vibration damper. It provides mechanical protection, thermal insulation, and oil retention, all while ensuring leak-proof operation. The shell’s size, material thickness, and weld quality contribute significantly to the structural... --- > Detailed should costing of semiconductor packaging shows how each step - die attach, bonding, molding, testing - contributes to IC packaging costs. - Published: 2025-08-26 - Modified: 2025-08-30 - URL: https://advancedstructures.in/how-to-do-should-costing-of-semiconductor-packaging/ - Categories: Consumer Electronics Product Studies In this blog, we focus on the semiconductor packaging stage inside an IC. We should-costed the entire process - from die singulation and lead frame prep to bonding, molding, testing, and tape-and-reel. The goal is to break down material, process, and overhead costs to show what really drives IC packaging economics. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. From die singulation to UDFN package a complete should-costing study of semiconductor packaging. This blog presents a detailed process study of semiconductor packaging, following every step from die singulation, lead frame preparation, and die attach to bonding, molding, testing, and final tape-and-reel. Through should-costing, we break down how each stage contributes to the overall cost of taking a semiconductor die to a finished IC package. An electronic chip or IC (Integrated circuit) is a compact, self-contained electronic component that performs specific functions such as processing, storage, control, or signal conversion in an electronic system. Semiconductor packaging can account for up to 30% of chip cost, yet sourcing teams often struggle to validate supplier quotes. Rising costs, opaque pricing, and limited transparency in materials, processes, and overheads make cost control challenging. That is why should costing of semiconductor packaging, including UDFN, QFN, and BGA types, is essential for clear cost visibility. Platforms such as xcPEP give cost engineers and procurement leaders fact-based clarity with standardized, transparent costing models—empowering faster, data-driven negotiations. An integrated circuit (IC) contains a silicon die that performs core functions, while the package provides electrical connections, insulation, and protection. ICs come in many package types—such as DIP, UDFN, QFP, BGA, CSP, SOIC, LGA, QFN, PGA, and TSSOP. This blog focuses on the manufacturing process and should-costing of the UDFN (Ultra-thin Dual Flat No-lead) package. UDFN (Ultra-thin Dual Flat No-lead) The Ultra Dual Flat No-Lead (UDFN) package is a thin, miniaturized version of the DFN, often under 0. 5 mm thick. With a flat, leadless body and metal pads on the underside, it saves board space, reduces profile height, and improves electrical performance by minimizing lead inductance. UDFN packages feature an exposed thermal pad for efficient heat dissipation, a molded body that protects the die, and short interconnects for high-frequency signal integrity. Their compact, lightweight design with strong thermal and electrical performance makes them common in mobile devices, wearables, RF modules, and other high-density applications. The images above illustrate the cross-sectional view (left) and the top view (right) of a silicon die attached to a lead frame in a UDFN package. The method of die attachment and the interconnection between the silicon die and the lead frame will be explained in detail later in this blog. UDFN Package Assembly Process The assembly of a UDFN package typically involves nine distinct process stages. The below image depicts all the processes involved. We conducted a Should Costing analysis for semiconductor packaging assembly in xcPEP, assuming a prefabricated silicon die. xcPEP is an intuitive and user-friendly platform equipped with comprehensive tools. The illustration below outlines the complete process—from die to final package—along with the cost distribution for a single IC. The image below illustrates the percentage cost contribution of each process, as analyzed using xcPEP Outlined below are the key processes involved in semiconductor packaging assembly. Each process has specific cost drivers, all of which have been incorporated into xcPEP. Die Singulation Die singulation is the process of separating individual dies from a wafer or molded substrate. It defines final die dimensions and prepares each die for packaging, requiring high precision to prevent chipping or damage as devices shrink and wafers thin. Types of die singulation:Blade dicingLaser dicingPlasma dicing Cost Drivers:Dicing method (saw, laser, plasma)Wafer thickness and material hardnessStreet width (saw street size)Yield loss due to chipping or crackingEquipment speed and precision Lead Frame Loader The lead frame loader is an automated system that supplies lead frames—thin metal structures used to support and interconnect the semiconductor die—into the assembly line. It ensures proper orientation, alignment, and continuous feeding of lead frames into subsequent processes such as die attach and wire bonding. Efficient operation of the loader minimizes downtime, reduces handling damage, and maintains consistent throughput in high-volume semiconductor packaging. In should costing of semiconductor packaging, the loader’s automation level, handling precision, and integration with other equipment are critical parameters that directly influence overall cost. Cost Drivers:Loader automation level (manual, semi-automatic, fully automatic)Lead frame type (material, thickness, plating)Handling precision and alignment requirementsEquipment speed and throughput capabilityMaintenance frequency and downtime impactIntegration with upstream/downstream assembly equipment Die Attach The semiconductor die is mounted onto the lead frame or substrate using adhesive materials or solder. Die attach is critical for mechanical stability and thermal performance. Types of die attach processesEpoxy die attachSolder die attachEutectic die attachSilver sintering die attachAdhesive film die attachThe die attach processes are classified based on the type of adhesive used. The image on the left Below illustrates a silicon die, adhesive layer, and lead frame. Die attach involves three... --- > Explore xcPEP, a modern should costing software that outperforms legacy costing tools with faster performance and region-specific accuracy. - Published: 2025-07-22 - Modified: 2025-09-08 - URL: https://advancedstructures.in/xcpep-best-should-costing-software/ - Categories: Guides See why manufacturers are replacing aPriori with xcPEP for faster, transparent, and more affordable should costing. Feature Legacy Costing Software xcPEP Data Accuracy Limited; databases often lack regional accuracy. Real-world accuracy; uses detailed manufacturing logic and region-specific rates. Transparency Opaque "black-box" calculations; difficult to trace the source of calculated costs. Full transparency; every assumption and calculation is visible, allowing users to drill down into cost drivers. User Experience Steep learning curve and heavy reliance on expert support. Easy to use; modular approach reduces the need for large cost-engineering teams or consultants. Cost of Ownership High cost, high licensing fees, and complex implementation. Lower total cost of ownership, typically one-third of legacy software. Technology Struggles with costing proprietary parts and PCBs; key process steps are missing. Can cost proprietary parts and PCBs without needing detailed 3D models. Data & Updates Averaged out data which doesn’t precisely reflect actual costs in a region. Specific researched data for every client, tailored to their regions of interest. Application Speed Slow. Fast and responsive, built on the latest tech stack. Architecture Often on-site and complex. Cloud-native design for faster performance and easier updates. Cost Justification Difficult to defend cost estimates due to lack of transparency. Allows users to defend their estimates by making all calculations visible. Introduction Manufacturers across automotive, off-highway, home appliance, electronics and machinery sectors have long relied on geometry-based costing software for should-costing and DFM analysis. However, many users have noted drawbacks. Common complaints include limited data accuracy, opaque “black-box” calculations, a steep learning curve, high complexity and cost, and heavy reliance on expert cost-engineering teams. For example, reviewers have pointed out that the material cost databases of CAD-driven cost modeling platforms often lack regional accuracy, and that key manufacturing process steps (like certain castings or assemblies) are missing. Others lament that it’s “difficult to find the source and formula” behind calculated costs, and that using 2D drawings is “cumbersome” since the tool was built for 3D models. High licensing fees and the need for expensive customization are also often mentioned – one cost analyst described such parametric costing software as “expensive and expert service” to use. In short, users report that achieving accurate, defendable cost estimates with these geometry-based costing tools can be slow, resource-intensive, and opaque – especially when projects demand region-specific data or fast implementation. Key pain points reported with Parametric Costing Software include:Data accuracy and currencyUsers wish geometry - based costing tools offered more up-to-date, location-specific material and labor rates. One engineer noted the tool’s database should better reflect “supplier market” costs to yield “closer to accurate/actual costing”. Limitation in costing of Proprietary Parts and PCBsWhen evaluating alternatives to CAD-centric costing platforms, a critical weakness often emerges: their reliance on readily available 3D models primarily limits its should-costing capabilities to internally designed components. This fundamental dependency means these tools frequently falters when tasked with costing proprietary parts—components with limited design data or supplied by third parties—and completely struggles with the complexities of PCB costing, where traditional 3D models are insufficient for accurate manufacturing cost analysis. This leaves a significant gap for companies needing comprehensive cost intelligence across their entire bill of materials, highlighting a major limitation of traditional parametric tools in real-world procurement and design-to-cost scenarios. Transparency and traceabilityThe software has been described as a “black box”, where it’s “difficult to find the source and formula behind” calculated cycle times and costs. This lack of visibility makes it hard to defend estimates. Ease of use and learning curveMany users struggle with the interface and workflow of cad-based costing tools. For example, 2D modeling is “cumbersome,” and advanced customization requires deep expertise. One user explained that significant “competency is required to get into the details of parameters behind the cost model. ”Implementation complexityDeploying a model-driven cost analysis system often demands large cost-engineering teams or consultants. Upgrades and custom integrations can be “painful” and require expert support. Pricing and cost of ownershipThe platform’s subscription and maintenance fees can be steep. Reviewers explicitly called out the “expensive” licensing and need for paid add-ons, forcing companies to build large business cases for approval. Limited process coverageFinally, some users find CAD-driven cost modeling platform offers incomplete process libraries. Reports mention missing capabilities for specialty parts (e. g. certain molds, fluids, assemblies) and an expanding machine database requirement. In sum, feedback from forums and verified reviews shows that that this type of legacy costing software—while powerfull – can be overkill or too opaque for many teams. These issues have led engineers and sourcing managers to explore alternatives. xcPEP is one such next generation should costing software which has taken an entirely different approach from first principles. How xcPEP Addresses Legacy Software's Pain Points The xcPEP platform emphasizes real-world accuracy, full transparency, ease of use, and lower costs. In practice, this means:Real-world process accuracyUnlike legacy parametric tools, xcPEP bases every cost model on detailed manufacturing logic and region-specific rates. As the... --- > Explore our in-depth teardown and should costing analysis of a 55HP agricultural tractor. Learn how to reduce tractor costs, optimize part manufacturing, and achieve significant savings through expert benchmarking and value engineering strategies - Published: 2025-06-20 - Modified: 2025-06-21 - URL: https://advancedstructures.in/tractor-cost-analysis-should-costing-benchmarking/ - Categories: Off Highway Product Studies Bring transparency to tractor manufacturing. Our teardown dissects key systems—engine, transmission, hydraulics—generating a detailed Bill of Materials and cost model. Using systematic costing (materials, machining, tooling, overheads), we establish a precise “should‑cost” baseline for each component Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Introduction: Navigating High Tractor Costs with Should Costing and Benchmarking The agricultural machinery sector in India continues to evolve rapidly, with rising demand for mid-range tractors that balance power, efficiency, and affordability. For both farmers aiming to reduce tractor ownership costs and manufacturers striving for competitive pricing, understanding the true cost of components is paramount. This in-depth analysis presents a complete teardown and should-costing analysis of a popular 55 HP diesel-powered agricultural tractor. We delve into this widely popular segment to estimate the Bill of Materials (BOM) and uncover the precise cost distribution across key tractor subsystems. Our goal is to provide actionable insights for tractor cost optimization, value engineering, and strategic sourcing through meticulous tractor parts benchmarking. 55HP Tractor Specifications: A Foundation for Cost AnalysisUnderstanding the specifications provides the context for our cost estimations. This 55 HP tractor, a common choice for small-to-medium landholding farmers, forms the basis of our tractor part should cost assessment. Parameter Details Engine Type Turbo-charged 3 Cylinder Direct Injection Engine Power 55 HP (41. 2 kW) Fuel Type Diesel Fuel Capacity 68 Liters Rated RPM 2100 RPM Clutch Type Dual Dry Clutch Gearbox Configuration 12 Forward + 4 Reverse Brake Type Oil immersed, Self-Adjusting, Self-Equalizing Hydraulic Lift Capacity 2000 kg Steering Type Power Steering Maximum Forward Speed 31. 9 kmph Maximum Reverse Speed 24. 5 kmph Maximum Creeper Speed 0. 87 kmph Emission Norms BS-V / Stage V Gearbox Type Full Constant Mesh / Synchromesh PTO Power ~46–47 HP Rear Axle Type Direct Drive Tyres Front: 6. 5x20, Rear: 16. 9x28 Drive Mode 2WD Price Segment ₹11. 15 to ₹ 12. 84 lakh Tractor Subsystem Architecture: Deconstructing for Cost InsightsThe tractor was meticulously disassembled into 10 functional subsystems. This process allowed us to better understand the internal layout, assembly complexity, and component-level interdependence, all critical factors for accurate should costing and benchmarking farm equipment. These include: Engine, After-Treatment System (ATS), Transmission & Driveline, Front Axle, Hydraulic System, Cab Operator Station, Electrical & Electronic Control Unit (ECU), Tyres & Wheels, and Tools & Accessories. Engine Subsystem: Core of Tractor Performance and CostAt the heart of the tractor lies a 3-cylinder diesel engine, optimized for rural field conditions. The cast-iron engine block, designed for high torque and long operational hours, contributes significantly to tractor manufacturing cost. The teardown revealed a direct-injection system. Supporting components include an air intake manifold, turbocharger, and a wet cylinder liner setup, all analyzed for their individual tractor engine parts cost. Transmission & Driveline: Key to Power Transfer and High CostsThe transmission system, featuring a full constant mesh or synchromesh setup with 12 forward and 4 reverse gears, is a major tractor cost driver. The teardown revealed forged steel gear clusters, oil-lubricated shafts, and a robust differential. The rear axle connects to the PTO output and is built for high torque transfer, making its cost analysis vital for tractor cost reduction. Hydraulic System: Essential for Implements and Cost EfficiencyOne of the most vital systems in a tractor, the hydraulic system is responsible for operating implements like rotavators, ploughs, and cultivators. The teardown exposed a gear-type hydraulic pump connected to the PTO, a draft control valve, and lift arms with a mechanical sensing mechanism. Understanding the hydraulic system cost is key to cost-effective tractor parts sourcing. Cab Operator Station: Ergonomics vs. Cost ImplicationsAlthough tractors in this segment are not cabin-equipped like their higher-end counterparts, the operator station is ergonomically designed for long working hours. The seat is suspension-mounted with adjustable back support. The steering column includes a console with analog or semi-digital instrumentation for RPM, fuel level, and PTO engagement status. Analyzing the operator station cost helps in identifying areas for tractor comfort feature cost optimization. Electrical & ECU: The Growing Role in Tractor CostThe tractor is equipped with a 12V electrical system that powers the lights, instruments, and starter motor. The teardown revealed a basic wiring harness, a 65–80Ah battery, alternator, and fuses. For BS-V emission compliance, an ECU is used to manage fuel injection and diagnostic protocols. The electrical system cost is a growing segment in tractor part should costs. After-Treatment System (ATS): Regulatory Compliance and CostThe BS-V emission regulations necessitate an after-treatment system, which in this tractor includes a Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF). Temperature and NOx sensors are mounted both upstream and downstream of the system for real-time emission monitoring. While low in weight, the ATS cost is critical for regulatory compliance in tractor manufacturing. Tyres & Wheels: Significant Contributor to BOM CostThe front tyres are 6. 5 x 20 and the... --- > Unlock significant cost savings in automotive, EV, and off-highway electronics. This comprehensive guide details should costing methodologies, from teardown analysis to AI-powered predictive costing, and shows how xcPEP software empowers cost control and innovation for maximum profitability. - Published: 2025-06-20 - Modified: 2025-06-20 - URL: https://advancedstructures.in/how-to-should-cost-electronics-automotive-ev/ - Categories: Guides Discover how xcPEP should cost analysis software empowers global commodity managers. Solve sourcing pain points, achieve cost optimization, and leverage real-time cost intelligence for strategic advantage. Introduction: Navigating the High-Stakes World of Automotive Electronics Costs and EV Cost OptimizationThe Escalating Role of Electronics in Modern VehiclesThe landscape of modern vehicle manufacturing is undergoing a profound transformation, driven significantly by the escalating integration of electronic systems. These sophisticated components are no longer merely supplementary features but are becoming the very essence of vehicle functionality, safety, and user experience. This pervasive integration has led to a dramatic increase in the proportion of electronics within a vehicle's total cost. Historically, in the 1970s, electronics represented only 5% to 10% of a car's price, primarily limited to basic functions like fuel injection. By the turn of the millennium, this figure had more than doubled to 22%, and by 2020, it reached approximately 40%. Projections for 2030 are even more striking, with electronics anticipated to account for up to 50% of a vehicle's value, and specifically in electric vehicles (EVs), potentially reaching 35% even when excluding battery systems. This exponential growth is fueled by the widespread adoption of advanced technologies such as Advanced Driver Assistance Systems (ADAS), complex infotainment systems, numerous Electronic Control Units (ECUs) managing diverse vehicle functions, and an array of environmental sensors. The Challenge of Cost Management in Software-Defined VehiclesThis rapid expansion of electronic content presents a critical challenge for manufacturers: how to effectively manage and control costs in an increasingly complex and dynamic environment. The traditional hardware-centric approach to cost analysis, while still fundamental for physical components, must evolve. The increasing prevalence of "Software-Defined Vehicles" (SDVs) means that software is no longer a static element but an evolving, continuous cost driver. The development, integration, and ongoing maintenance of automotive software, including over-the-air (OTA) updates and cybersecurity measures, introduce significant and often less transparent cost implications. Software, unlike hardware, does not simply degrade; it continuously evolves or decays based on how it is managed, necessitating a more holistic costing methodology that accounts for both the tangible hardware and the intricate, dynamic software components. Should Costing: A Strategic Imperative for Cost ControlIn this high-stakes environment, "should costing" emerges as a strategic imperative for achieving robust cost control and sustaining competitive advantage. Should costing, also known as cost breakdown analysis, is a powerful methodology that employs "clean-sheet" techniques to generate a bottom-up estimate of a supplier's true production costs and margins. Its primary objective is to differentiate between the quoted price of goods or services and their inherent, true value. This method involves meticulously dissecting a product into its fundamental components and analyzing the costs associated with raw materials, labor, manufacturing processes, overheads, and profit margins. It has earned its reputation as the "gold standard" for hardware purchases within the automotive industry. This approach represents a significant shift from reactive cost management to a proactive strategy. Should-cost analysis enables organizations to estimate product costs before a Request for Proposal (RFP) is even issued, thereby establishing a crucial benchmark for evaluating competitive bids. This proactive stance is vital for advanced companies aiming to optimize profitability during the design phase, where cost is effectively "baked" into the product, rather than attempting to reduce costs downstream after significant investments have been made or supplier commitments finalized. This upstream integration of cost management provides a substantial competitive advantage in rapidly evolving sectors. This guide will provide a comprehensive roadmap, detailing the step-by-step process of implementing electronics should costing. It will address common challenges faced by manufacturers, explore advanced techniques and emerging trends, and demonstrate how the xcPEP software can empower organizations on this critical journey towards mastering cost control and driving innovation in automotive, EV, and off-highway electronics. What is Electronics Should Costing? Defining True Value for Automotive and EV ComponentsBeyond the Quote: The Clean-Sheet Approach to Electronics Cost EstimationAt its core, should costing is a methodology that fundamentally redefines how product costs are understood and managed. It moves beyond simply accepting a supplier's quoted price or comparing various bids. Instead, it relies on a "clean-sheet, bottom-up model of the production process" to accurately estimate what a product should cost under optimal, efficient, and competitive market conditions. This provides an objective, fact-based benchmark for price negotiations with suppliers. The power of this approach lies in its ability to dissect complex product costs, transforming what might appear as a "black box" into a transparent, granular breakdown of all relevant cost drivers and deliverables. For intricate electronic assemblies, where costs can easily be obscured by aggregated pricing, this level of transparency is indispensable for effective management. Detailed teardowns of components like motor controllers and radar sensors illustrate how granular analysis of Bill of Materials (BOMs), material composition, and manufacturing processes reveals precise cost drivers, allowing for targeted optimization. Core Components of Electronics Should Cost: Materials, Labor, Overheads, and ProfitA comprehensive should-cost analysis meticulously itemizes the cost of a product into its various constituent elements, commonly referred... --- > Discover how xcPEP should cost analysis software empowers global commodity managers. Solve sourcing pain points, achieve cost optimization, and leverage real-time cost intelligence for strategic advantage. - Published: 2025-06-16 - Modified: 2025-06-17 - URL: https://advancedstructures.in/global-commodity-managers-should-cost-software/ - Categories: Guides Discover how xcPEP should cost analysis software empowers global commodity managers. Solve sourcing pain points, achieve cost optimization, and leverage real-time cost intelligence for strategic advantage. Introduction: Navigating the Complexities of Global Sourcing in Today's LandscapeGlobal commodity managers operate at the forefront of increasingly volatile and complex supply chains. Their role has evolved significantly beyond mere transactional purchasing, now encompassing strategic value creation, proactive risk mitigation, and fostering innovation across diverse international markets. In the contemporary economic landscape, characterized by intense global competition, rapid economic shifts, and unforeseen disruptions, the imperative for precise cost control and strategic sourcing has reached unprecedented levels. Modern commodity managers are no longer simply buyers; they are strategic architects tasked with ensuring business continuity and competitive advantage. The daily responsibilities of global commodity managers involve navigating a gauntlet of complex hurdles. These include intricate logistical challenges, the pervasive threat of geopolitical instability, and the perennial struggle for cost transparency and consistent quality across a dispersed supplier base. Such challenges frequently compound, making effective decision-making exceptionally difficult without the appropriate tools and intelligence. Advanced Structures India (ASI) offers a transformative solution to these challenges through its xcPEP ecosystem, a leading should cost analysis software and cloud-native platform designed to revolutionize cost analysis and procurement. This powerful platform is underpinned by xcPROC, a dynamic data and insights hub that provides continuously updated and verified market intelligence. This report will delve into the core pain points confronting global commodity managers and illustrate how these cutting-edge technologies offer a robust blueprint for precision sourcing, optimal cost management, and a significant strategic advantage in a dynamic global market. Challenge Area Specific Pain Point Impact on business Supply Chain Volatility & Disruptions Complex logistics, geopolitical instability, unforeseen events, raw material shortages Production delays, missed deadlines, increased operational costs, brand reputation damage "Black Box" Costing & Pricing Outdated/generic data, lack of transparency, difficulty with complex parts, inaccurate cost targets Suboptimal pricing, missed cost savings, strained negotiations, inability to validate quotes Quality & Supplier Reliability Inconsistent product quality, supplier reliability issues, vendor management challenges Product integrity risks, reverse supply chain costs, brand damage, critical production delays Regulatory Compliance & Trade Barriers Complex regulatory frameworks, protectionism, ethical/social responsibility concerns, maintaining compliance Legal repercussions, financial penalties, import restrictions, brand reputation damage Inefficient Negotiation & Vendor Management Data-poor negotiations, communication barriers, balancing cost/quality, lack of process visibility Missed value opportunities, prolonged negotiations, erosion of supplier trust The Unseen Hurdles: Sourcing & Pricing Pain Points for Global Commodity ManagersGlobal commodity managers face a multifaceted array of challenges that complicate sourcing, inflate costs, and introduce significant risks. These issues often intertwine, creating a complex operational environment. Supply Chain Volatility & Disruptions: The New NormalThe modern supply chain is inherently volatile, marked by frequent and often unpredictable disruptions. Specific Pain PointsGlobal commodity managers must grapple with an intricate web of complex logistics, which includes diverse regulations, customs procedures, import duties, taxes, tariff classifications, and extensive documentation across numerous countries. Developing nations frequently present additional layers of complexity, such as lower logistics performance and heightened risks of cargo theft. Beyond these procedural hurdles, the global landscape is rife with potential disruptions stemming fromGeopolitical instability and unforeseen eventsThese can range from geopolitical tensions and natural disasters to trade disputes, labor issues, and global crises like the COVID-19 pandemic or the grounding of a container ship in the Suez Canal. Such events inevitably lead to significant delays, material shortages, and escalating costs. 1 Furthermore, the availability of criticalRaw materialsRaw materials can be severely impacted by disrupted global shipping routes or unforeseen events affecting production, such as disease outbreaks hitting agricultural commodities or conflicts impacting factories. 4Impact on BusinessCollectively, these challenges result in severe production delays, missed deadlines, substantial increases in operational costs, and potential damage to brand reputation due to unfulfilled commitments or quality issues. 5Broader ImplicationsThe various research sources consistently highlight that logistical complexities are not isolated issues but are often exacerbated by, and deeply intertwined with, geopolitical instability and natural disasters. This interconnectedness creates a cascading effect on material availability, costs, and delivery times. For instance, a geopolitical event can directly impact shipping routes, leading to logistical bottlenecks and subsequent raw material scarcity. This indicates that a solution addressing only one facet, such as merely cost, without considering the broader supply chain resilience and the interplay of these risks, will be inherently limited. Commodity managers require tools that provide holistic visibility and intelligence across these interdependent risk factors to truly mitigate their impact. The pervasive and constant threat of disruptions necessitates a fundamental shift in strategy for global commodity managers: moving from merely reacting to crises to proactively identifying, assessing, and mitigating potential risks. The frequent and severe impact of supply chain disruptions underscores this need. Reactive problem-solving, such as scrambling to find a new supplier after a disruption hits, is inherently costly, time-consuming, and often leads to suboptimal outcomes. Proactive risk management, enabled by robust data and intelligence, allows for pre-planning—for example, diversifying suppliers, building... --- - Published: 2025-05-20 - Modified: 2025-06-23 - URL: https://advancedstructures.in/hydraulic-motor-teardown-and-should-costing/ - Categories: Off Highway Product Studies Deep-dive teardown and cost analysis of a hydraulic motor. Includes internal component breakdown, BOM, and should-cost estimation to guide sourcing and engineering decisions. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Introduction: The Strategic Imperative of Hydraulic Motor Teardown and Should Costing for Industry Leaders Hydraulic motors stand as foundational components across a myriad of heavy-duty applications, particularly within the demanding realm of off-highway vehicles such as excavators, loaders, harvesters, and mining machinery. These vital actuators are engineered to convert hydraulic pressure into mechanical energy, efficiently delivering the torque and rotation indispensable for driving complex machinery. In an increasingly competitive global market, understanding the intricacies of these components, both mechanically and economically, is not merely advantageous but strategically imperative. This report details a comprehensive study of a hydraulic motor, conducted entirely in-house by ASI Engineering. The primary objective of this analysis was to demonstrate the robust capabilities of the xcPEP® platform, utilizing an independently procured product for an unbiased assessment. This methodology, encompassing both a thorough teardown and a meticulous should cost analysis, provides a dual benefit for organizations. The teardown offers granular insights into design and construction, revealing the physical architecture and material choices. Concurrently, the should cost analysis translates these physical attributes into precise financial implications, offering a clear understanding of manufacturing expenses. Together, these analytical approaches form a powerful combination, providing a holistic perspective crucial for optimizing a product's entire lifecycle, from initial design considerations to final procurement strategies. Furthermore, the systematic application of such analytical techniques, as exemplified by this study and the capabilities of the xcPEP® platform, positions an organization as a leader in product lifecycle management and cost optimization. For companies striving to enhance their product lines or streamline their supply chains, comprehending how these detailed analyses are executed and the tangible value they yield—such as cost reduction, performance enhancement, or material optimization—is paramount. This elevates teardown and should costing from mere analytical exercises to strategic instruments, enabling companies to secure a significant competitive advantage by refining product cost structures and boosting operational performance in the market. Understanding Hydraulic Motors: Fundamentals, Types, and Key Applications in Heavy-Duty Machinery To fully appreciate the depth of a hydraulic motor teardown and should cost analysis, a foundational understanding of these mechanical actuators is essential. This section delineates their core function, explores common types prevalent in off-highway applications, and highlights their critical performance characteristics and widespread uses. What is a Hydraulic Motor? At its core, a hydraulic motor functions as a mechanical actuator designed to convert hydraulic energy—derived from fluid pressure and flow—into rotary mechanical energy, manifested as torque and rotation. This conversion is fundamental to the operation of countless industrial and mobile machines, enabling the precise and powerful movement of heavy loads. Common Types of Hydraulic Motors in Off-Highway Vehicles The landscape of hydraulic motors used in off-highway vehicles is diverse, each type offering distinct advantages for specific applications. Common configurations include Gear Motors (both External and Internal), Piston Motors (Axial and Radial), Vane Motors, and Gerotor/Geroler Motors. This variety underscores the specialized demands of heavy machinery, where different operational requirements necessitate tailored motor designs. Applications and Performance Characteristics Hydraulic motors are indispensable in a wide array of heavy-duty machinery, including excavators, loaders, skid steers, harvesters, and mining equipment. Their widespread adoption is attributable to a suite of key features that make them exceptionally suited for demanding environments. These features include variable displacement, which allows for flexible operation; a high-pressure range, typically up to 450 bar continuous and 500 bar peak; and a bent-axis design, which contributes to higher efficiency and power density. They also boast a wide displacement range, from 28 to 1000 cm³, offer modular options for easy integration, and possess high-speed capability, often with optional flushing and boost pressure features. These technical attributes translate into significant operational benefits. Hydraulic motors are highly valued for their ability to deliver high torque at low speeds, their compact size for seamless integration into machinery, and their variable displacement, which enhances overall efficiency. Their robust design ensures reliable performance even in the most arduous and harsh environments, making them a cornerstone of heavy-duty vehicle operation. The engineering choices, such as the bent-axis design and variable displacement, are not arbitrary; they represent a direct response to the rigorous demands of off-highway vehicles, which require robust power delivery, precise control, and durability in challenging conditions. This continuous engineering effort to optimize motors for specific industrial challenges highlights why detailed analyses, such as teardowns, are crucial for understanding these design choices and identifying pathways for further innovation or competitive benchmarking. Inside the Machine: A Detailed Hydraulic Motor Teardown This section delves into the specifics of the hydraulic motor teardown, focusing on the particular product chosen for the study and... --- - Published: 2025-05-19 - Modified: 2025-06-04 - URL: https://advancedstructures.in/omron-bp-monitoring-device-hem-7120-teardown-bom-and-should-costing/ - Categories: Consumer Electronics Product Studies Detailed teardown and Bill of Materials (BOM) analysis of the Omron HEM-7120 digital blood pressure monitor. Understand manufacturing costs and product design insights. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. This article is a product of an internal study conducted by our engineers. All rights belong to Advanced Structures India Private Limited. Prominent Features of Blood Pressure Monitoring Device A comprehensive teardown and benchmarking of the blood pressure monitoring device was conducted, analyzing 35 features, specifications, and product-level details. Highlighted below are some of the standout features:This compact device offers one-touch, fully automatic operation using oscillometric measurement for blood pressure and pulse readings. It features electronic inflation/deflation, dual power modes (battery/AC), an LCD display, memory storage, and built-in error detection—ideal for home, clinic, or outreach use. Operation Type: Fully automatic with one-touch start and stop Power Source: Dual-mode: Operates on 4×AA batteries or via AC adapter Measurement Range – Pressure: 0 to 299 mmHg Measurement Method:Oscillometric method for non-invasive blood pressure detection Error Indicators in the Automatic Blood Pressure Measurement Device The device features 11 LCD error indicators to alert users of issues like cuff misplacement, movement, irregular heartbeat, or low battery, ensuring accurate and reliable readings. Below are some of the key error indicators displayed by the device: E1 Error: Inflating Error Irregular Heartbeat Indicator E3 Error: Cuff Inflation Issue Measurement Accuracy of Automatic Blood Pressure Measurement Device The device offers clinically reliable measurement accuracy, with a pressure tolerance of ±3 mmHg and pulse rate accuracy within ±5% of the displayed reading. This ensures consistent and dependable results for home and clinical use alike. Piezoresistive Sensor Used in the Automatic Blood Pressure Measurement Device The Automatic Blood Pressure Measurement Device features the 2SMPP-02 pressure sensor from Omron Electronics. This is a compact low-pressure piezoresistive sensor with a range of up to 5. 37 PSI (37 kPa). Key features include: 0. 1" male tube port Analog output range of 0–31 mV Vented gauge design Small 6-SMD module footprint Working Principle: The sensor contains a flexible diaphragm integrated with a piezoresistive material. As the diaphragm deforms under pressure, the resistance of the embedded material changes. This resistance change is converted to a low-voltage analog signal proportional to the applied pressure. The signal is then digitized and processed by the microcontroller. Microcontroller Used in the Automatic Blood Pressure Measurement Device Powering the core functions of the device is Toshiba’s TMPM332FWUG(C) microcontroller, based on the ARM Cortex-M3 architecture. Flash Memory: 128 KBSRAM: 8 KBIt processes pressure sensor data, drives the LCD interface, and manages user interactions—all while supporting low-power operation suitable for portable medical use. Functioning of Automatic Blood Pressure Measurement Device The device operates in two main phases: Inflation and Deflation, with critical coordination between the power system, electronic circuitry, microcontroller, air pump, valve, and pressure sensor. Cuff Inflation – Pressurization Phase START Button Pressed (①): The user presses the Start/Stop button, sending a signal through the Start/Stop Switch PCB(②) to the controller. Power Supplied (③ & ④): The 1. 5V alkaline batteries supply power via the Battery Power Supply PCB, energizing key components — the Rolling Pump, Valve, and Controller PCB. Valve Remains Closed (⑥): During inflation, the Solenoid Valve is energized, keeping it closed to prevent air from escaping. The valve coil is powered (6V), which pulls a plunger inside the valve to block the air outlet. This ensures all air from the pump is directed only to the cuff, not vented out. Pump Starts (⑤): The Rolling Pump begins pushing air through the connected tubing system. Air Routed via Duct and Plug (⑦ & ⑨): The air travels through the Air Duct and Air Plug, inflating the Cuff wrapped around the user’s upper arm. Pressure Monitoring Begins (Sensor): The 2SMPP-02 Piezoresistive Pressure Sensor continuously monitors the cuff pressure. It detects changes in pressure by deforming under mechanical force, altering electrical resistance. This change is converted to an analog voltage proportional to the cuff pressure. Signal Processing by Controller PCB (⑧): The sensor’s analog voltage is sent to the Toshiba ARM Cortex-M3 microcontroller on the Controller PCB. It digitizes the signal, compares it with the programmed threshold. It adjusts pump operation accordingly. Inflation Stops at Target Pressure: The pump continues until the pressure exceeds a pre-set systolic threshold (e. g. , ~180 mmHg), after which the controller stops the pump while keeping the valve closed. Fallback Mechanism – Additional Inflation if Needed: If the preset target pressure does not fully occlude the artery, and pulsations are still detected, the controller resumes inflation in small increments. The pressure continues rising until: Arterial blood flow stops completely (no oscillation detected), or The device hits the maximum safe pressure limit (typically around 280–300 mmHg). Cuff Deflation – Depressurization Phase Valve... --- > We have conducted a detailed teardown of a power bank, mapped its bill of material and calculated its should cost. - Published: 2025-05-17 - Modified: 2025-05-26 - URL: https://advancedstructures.in/mi-powerbank-3i-teardown-and-should-costing/ - Categories: Consumer Electronics Product Studies We have conducted a detailed teardown of a power bank, mapped its bill of material and calculated its should cost. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Teardown and Should Costing of Mi Power Bank 3i This is Mi Power Bank 3i 20000 mAh, 18W with Fast Charging (PD) Prominent Features of Mi Power Bank 3i A detailed teardown and benchmarking of the Mi Power Bank 3i 20000 mAh was conducted, mapping 10 features, specifications, and information at the product level. Some of the prominent features are detailed below: Battery Cell in a Power Bank The Mi Power Bank 3i houses two lithium-ion Polymer cells arranged in parallel configuration, providing multiple charge cycles for smartphones, tablets, and other devices. This design ensures reliable, long-lasting performance. The cells are encased in a compact plastic tray with the following attributes: Type:Lithium-ion Polymer (High Density Batteries). The cells are rechargeable. Capacity per Cell:Each cell has a capacity of 10000 mAh and two cells are sandwiched to get 20000 mAh capacityConfiguration:2P (Two cells in Parallel configuration). The cells are sandwiched together inside the power bank Safety Features: Built-in over-chargeOver-dischargeThermal protection Power Bank Circuit Protection Features Safety is a cornerstone of the Mi Power Bank 3i. The device incorporates a twelve-layer circuit protection system, ensures maximum safety for both the power bank, and connected devices. The 12-layer circuit protection system that includes: Over-current ProtectionOver-charge and Over-discharge ProtectionShort Circuit ProtectionTemperature ProtectionReset mechanism for power recovery in abnormal conditions Charging Technology used in Power Bank The Mi Power Bank 3i offers dual input (Micro-USB and USB-C) and triple output (USB-A and USB-C), allowing simultaneous charging of three devices. With 18W fast charging, it delivers quick power to compatible devices, while the low-power mode ensures safe charging for delicate gadgets like fitness trackers, activated with a double-press of the power button. Fast Charging:Supports 18W fast charging with Power Delivery (PD) technologyDual Input Ports:Micro-USB and USB-C inputs for versatile chargingDual Output Ports:Two USB-A and one USB-C output ports supporting simultaneous charging. Trickle Charging Mode:Dedicated mode for low-power devices such as smartwatches and Bluetooth earbuds Mi Power Bank 3i Enclosure Design Our teardown of the Mi Power Bank 3i reveals its meticulous internal design, highlighting high-quality components and advanced safety mechanisms. The Mi Power Bank 3i features a durable ABS plastic enclosure with a sleek matte finish for heat resistance and scratch protection. The components are securely assembled using Adhesive Padding and DSA (Double-Side Adhesive) for enhanced durability and a compact, seamless design ensures easy portability for on-the-go convenience. Housing Material of Power Bank:High-strength ABS (Acrylonitrile Butadiene Styrene) plastic for durability and heat resistanceFeel and Finish of Power Bank:Matte finish for a premium feel and scratch resistancePower Bank Dimensions and Weight:150 x 72 x 26 mm, compact for portability and lightweight approximately 508 grams Bill of Materials (BOM) of Power Bank We conducted a detailed teardown of the Mi Power Bank 20000mAh to study its components and system architecture. This teardown study involved analyzing data related to various part attributes, enabling a comprehensive understanding of its design and functionality. Multi-level BOM (Bill of Materials) Structure of Power BankAfter teardown for this analysis, we used a Multi-level BOM (Bill of Materials) structure, which provides detailed insights into the main assemblies, their sub-assemblies, and individual components. Summary of Assemblies and ComponentsThe BOM (Bill of Materials) structure for the Mi Power Bank 20000mAh, with the number of assemblies and their child components, is summarized in the table below: Above image is of xcPEP BOM (Bill of Material) page view Power Bank Teardown and Detailed BOM (Bill of Materials) Analysis Total Assemblies and ComponentsAfter teardown, 3 assemblies and 43 components were identified in the Mi Power Bank 20000mAh. Component Parameters:Additionally, 40 BOM (Bill of Materials) parameters such as weight, dimensions, material type, electrical specifications, and thermal properties were mapped. On average, 20 parameters per part were recorded, depending on the complexity of the component. Power Bank Weight Distribution Analysis Weight Distribution Overview Total Weight and Assembly Breakdown The total weight of the Mi Power Bank 3i (including power bank, packaging, USB cable) is 508 grams. The weight distribution of the assemblies is as follows: Power Bank: 85. 86% (436 grams)Packaging:12. 18% (62 grams)Accessories: 1. 96% (10 grams) Teardown and Weight Contribution Insights Major Components Weight Contribution Rechargeable Polymer Cell: 73% (339. 99 grams)Bottom Cover: 10% (45. 27 grams)Packaging (Inner Box and Outer): 12. 3% (57. 4 grams)Top Cover: 4. 7% (22. 09 grams) Power Bank Weight Pareto Analysis Pareto Analysis of Component Weight Weight Pareto Insights from Teardown and Benchmarking of Power Bank The Rechargeable Polymer Cell is the heaviest component, weighing 339. 99 grams (73% of the total weight). The Bottom Cover contributes 45. 27 grams (10%... --- > We have conducted a detailed teardown of a bluetooth neckband headphone, mapped its bill of material and calculated its should cost. - Published: 2025-05-17 - Modified: 2025-07-30 - URL: https://advancedstructures.in/bluetooth-earphone-teardown-bom-should-costing/ - Categories: Consumer Electronics Product Studies We have conducted a detailed teardown of a bluetooth neckband headphone, mapped its bill of material and calculated its should cost. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Bluetooth Neckband Earphone: Teardown, Bill of Material & Should Costing and Analysis Prominent Features of Bluetooth Neckband Earphone A detailed teardown and benchmarking of the boAt Rockerz 255 Pro Bluetooth earphones were conducted, mapping key features, specifications, and information at the product level. Below are some of its prominent features: Audio Drivers and Performance of Bluetooth Neckband Earphone The boAt Rockerz 255 Pro is equipped with dynamic audio drivers that deliver high-quality sound. Key attributes include: Type:Dynamic audio drivers designed for bass-rich performance. Driver Size:Driver Size: 10 mm drivers providing immersive audio clarity. Frequency Response:Supports a wide range of frequencies for detailed sound reproduction. Impedance:16 ohms for enhanced compatibility with various devices. Bluetooth Neckband Earphone Connectivity Detailed teardown and analysis show that the earphone is equipped with Bluetooth 5. 0 technology, these earphones offer:Faster Pairing:Quick and reliable device connectivity. Extended Range:Up to 10 meters of stable connection. Dual Device Pairing:Simultaneous connection to two devices for convenience. Battery and Charging Technology of Bluetooth Neckband Earphone The Mi Power Bank 3i offers dual input (Micro-USB and USB-C) and triple output (USB-A and USB-C), allowing simultaneous charging of three devices. With 18W fast charging, it delivers quick power to compatible devices, while the low-power mode ensures safe charging for delicate gadgets like fitness trackers, activated with a double-press of the power button. Earphone Teardown and benchmarking activity show that the Rockerz 255 Pro features a high-capacity rechargeable Lithium-Polymer battery. Battery Life: Up to 6 hours of playtime on a full charge. Fast Charging: 20 minutes of charge provides 4 hours of playback. Charging Port: Micro-USB charging interface for universal compatibility. Safety Features: Overcharge and temperature protection for long-term durability. Design and Comfort of Bluetooth Neckband Earphone The teardown of boAt Rockers 255 Pro shows the earphones are designed for all-day use, focusing on comfort and durability. Housing Material of Bluetooth Neckband Earphone: Lightweight PP housing for ergonomic fit. Feel and Finish of Bluetooth Neckband Earphone: Matte exterior for a premium feel and scratch resistance. Bluetooth Neckband Earphone Cable: Flexible, tangle-free cable with in-line controls for ease of use. Magnetic function of Bluetooth Neckband Earphone: Secure fit: Magnet Keep the earbuds together when not in use, reducing tangling. Enhanced Portability: Easy to store and carry without worrying about misplacing them. Teardown Analysis of Bluetooth Neckband Earphone A meticulous teardown and benchmarking of the boAt Rockerz 255 Pro reveals the internal structure and component organization, showcasing its efficient design. Housing and Enclosure Design of Bluetooth EarphonesThe teardown and benchmarking activity shows that the boAt Rockerz 255 Pro features a durable PP plastic enclosure with a sleek matte finish for heat resistance and scratch protection. Housing Material of Rockerz 255 Pro Earphone:Lightweight PP plastic housing for durability and heat resistance. Rockerz 255 Pro Earphone Accessories:1 x USB Cable (USB A to USB C type)2 x Large Size Earbuds2 x Small Size Earbuds Printed Circuit Board and Electronic Child Components of Bluetooth Neckband Earphone The PCB within the earphones handles audio processing and connectivity. Key observations include: Bluetooth Chipset: Integrated Bluetooth 5. 0 chip for seamless pairing and audio transmission. Audio Drivers: Precision 10mm drivers for clear sound output. Battery: Compact Lithium-Polymer cell with a capacity of 110 mAh. Protection Circuits: Safeguards against overcharge, short circuit, and overheating. Weight of Bluetooth Neckband Earphone Total Weight of Bluetooth Neckband Earphone Approximately 26. 69 grams for the earphone and 100 grams with packing box and accessories. Bill of Materials (BOM) Analysis of Bluetooth Neckband Earphone The teardown and benchmarking study involved a detailed BOM analysis, mapping various assemblies and components. Below is an overview: Summary of Assemblies and Components We conducted a detailed teardown of the boAt Rockerz 255 Pro neckband earphone to study its components and system architecture. This teardown study involved analyzing data related to various part attributes, enabling a comprehensive understanding of its design and functionality. Multi-level BOM (Bill of Materials) Structure of Neckband Earphone After teardown for this analysis, we used a Multi-level BOM (Bill of Materials) structure, which provides detailed insights into the main assemblies, their sub-assemblies, and individual components. Summary of Assemblies and Components of Neckband The BOM (Bill of Materials) structure for the boAt Rockerz 255 Pro neckband earphone, with the number of assemblies and their child components, is summarized in the table. Above image is of xcPEP BOM (Bill of Material) page view Neckband Earphone Teardown and Detailed BOM (Bill of Materials) Analysis Total Assemblies and Components After teardown, 3 assemblies and 57 components were identified in the boAt Rockerz 255 Pro neckband earphone. Component Parameters: Additionally, 40... --- > Our engineers have benchmarked a BLDC motor used in an electric scooter to study its design, BOM and then conducted a zero-based costing exercise on it to get its direct material cost. - Published: 2025-05-17 - Modified: 2025-05-26 - URL: https://advancedstructures.in/bldc-brushless-direct-current-hub-motor-teardown-detailed-comparison-for-cost-reduction-insights/ - Categories: Automotive Product Studies, Home Appliances Product Studies Our engineers have benchmarked a BLDC motor used in an electric scooter to study its design, BOM and then conducted a zero-based costing exercise on it to get its direct material cost. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. We conduct detailed teardown study of electric vehicle drive motors typically for two purposes:Cost and engineering inputs for new product development. Cost reduction study of existing products by comparative teardown study. Cost insights are generated to understand the cost drivers, supply chain strategies and metrics, commonality study and more. Engineering insights are generated for study or packaging, integration, interface with other subsystems and more. Recently we conducted a teardown for VA/VE exercise on BLDC hub motors from OEM-A & OEM-B, while doing so we’ve devised a strategy to reduce the cost of BLDC hub motor used in automotive 2W application. We at Advanced Structures India use Engineering Intelligence and xcPEP tool to map data i. e. , material, architecture, manufacturing, complexity and cost. The cost drivers are compared up to the last level of detail & ideas for cost reduction are generated. This blog will focus on our findings while BLDC motor comparison in following areas:BLDC motor architecture study & its comparisonStator & Rotor assembly studyStator-Slot area and fill factorInsulation Liner & WedgeLaminationWindingRotor-MagnetHousingMotor housing & other structural componentsxcPEP’ s role in cost reduction BLDC motor architecture study & its comparison Motor A Motor B The architecture of both 3-Phase BLDC HUB motors was observed to be similar. However, the specification of motor A was observed to be on the higher side. Refer the following table for specifications. Motor A of 350 W, 36V is provided with a rated efficiency of 85% and RPM range of 250-800, whereas Motor B is a 300 W, 36V motor with rated efficiency of 80% and RPM range of 250-800. The construction of motor was same in both, where casted aluminium housing, rotor, stator and wheel were present, however packaging was observed to be different. Aluminium housing on motor B was of lower wall thickness compared to motor A by 2 mm. Packaging of housing plate on wheel is done using Allen bolts in both the motors but Motor A has used 17 bolts compared to 12 in Motor B. The inner stator reinforcement plate was stamped in both the motors whereas in Motor B it was of lower thickness value by 0. 2 mm and joined together with 6 spot welds compared to 12 rivets used in Motor A. Stator & Rotor assembly study Slot area and fill factor The slot area available in motor A was 26% larger, although the slot fill factor was lower by 8% (excluding insulating slot liner and other components). The larger slot area leads to lower yield of stator plate material hence increasing the raw material cost of the product. Also on the other hand, lower slot fill factor affects the electromagnetic force when compared to motor B where slot fill factor is higher by 8%. Maintaining a higher slot fill factor is difficult and has higher manufacturing cost but it improves the motor performance hence we need trade off wisely. Reducing the slot area will increase the yield of material used by 7% and also reduces machining process cost by 4%, this will overall save the cost of stator by 4. 8%. Slot insulator liner and wedge Both the stator used a class F insulation paper, but the thickness of paper used in motor B is 0. 05 mm less. Also, a wooden wedge was used in stator A compared to a plastic wedge in Motor B. On estimations we found that the cost of wedges is same but life of the wedge for stator B is higher. On reducing the thickness of insulation paper, the cost can be reduced but need to study wear and tear of the material in the thermal cycle of the stator. Refer the shape, size and location of usage for motor A and B in the below Fig. Stator lamination The lamination was found to be similar in terms of material type used and manufacturing process, also we found both to have spiral round layout of plate. The number of spiral available in stator for motor A was higher by 2 quantities, also the thickness of the spiral plate observed to be higher by 0. 15 mm. The lower thickness plate will avoid the hysteresis loss but it will increase the material & manufacturing cost. Here we need to carefully decide the tradeoff between the loses and cost. Refer the below fig for shape of the stator slot and spiral arrangement of stator. A higher thickness value of stator plates can be used to reduce the cost of material, but we need to also compensate the performance loss... --- > This is a blog about benchmarking features, BOM and architecture of an electric vehicle battery pack. This also includes study of all direct costs of the li ion EV battery pack by zero based costing method. - Published: 2025-05-17 - Modified: 2025-05-26 - URL: https://advancedstructures.in/ev-battery-pack-teardown-study-should-costing/ - Categories: Automotive Product Studies This is a blog about benchmarking features, BOM and architecture of an electric vehicle battery pack. This also includes study of all direct costs of the li ion EV battery pack by zero based costing method. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. We conduct detailed teardown study of electric vehicle battery packs typically for two purposes:Cost and engineering inputs for new product development. Cost reduction study of existing products by comparative teardown study. Cost insights are generated to understand the cost drivers, supply chain strategies and metrics, commonality study and more. Engineering insights are generated for study or packaging, integration, interface with other subsystems and more. With growing ecosystem of electric vehicles, demand for better battery pack performance is increasing to provide higher energy density and lifecycle from pack. Battery cells form a major portion of a battery pack, but cell alone cannot guarantee a better performance, as it is very sophisticated. Thus, to utilize battery cells in an optimized way, keeping cost under check, there are multiple parameters that need to be studied to design a battery pack. Below is the flow of a study on battery pack which was used as input for design & selection of the battery pack for a vehicle. Battery Pack detailed study Schematics of the battery pack To start with the first step is to study the battery pack at the assembly level and generate a detailed Layout/schematic to understand the setup and design philosophy. EV battery module study In this we study the arrangement of battery cells in a battery pack based on modules and type of connecting buses. For our sample teardown battery following is the sample representation of a cell module– Cells in a module are connected using a thin steel plate (spot welded to cell) and each module is connected using copper bus bars with a mounting screw to plastic modular cell holders. Modularity in packaging of battery pack Cells can be increased to more modules without designing new battery holder setup by using the modular battery cell connectors. Modular setup is required for cylindrical cells as their individual capacity is very less but provides flexibility in capacity. Connections & harness in the battery Wire connections, Module connection setup and Terminal details are studied to understand the overall setup for voltage and current output battery is supposed to provide. This study also gives an understanding of the type of mapping BMS is providing on the battery modules based on connection layout. Electrical Layout to be drawn for parallel and series. PCB Protection is studied on benchmark battery pack to understand the type of exposure is expected and the type of protection available using PCB coating. This layer looks like a transparent polish over the board and its thickness is calculated in teardown to understand cost and procedure. This type of layer mainly provides two benefits: –Saves the PCB board from corrosive elements and fluids and avoids failure due to humidity, corrosion, short circuits, etc. To provide higher electrical insulation for PCB’s own components which help in high voltage circuit. BMS & electronics set-up BMS for following parameters is studied in the teardown parts based on PCB and connection study, Cell Balancing – this is studied based on the connections by understanding the module level and cell level connections to PCB/BMS board. Charging and Discharge Management – Connection study helps in understanding the charge/discharge protection availability, whether it is at cell level or module level. Circuit Protection provisions – type of switches- mosfets, etc. Data Storage – BMS stores the data points which are stored to use later for troubleshoot/check usage pattern. Other sensors used for thermal, impact and humidity mapping to save battery pack Type of controller chips and arrangements. Sensors & data acquisition in EV battery Can be done using a memory card. – In the existing battery memory card arrangement was used to store the data and during charging after battery swapping this data is being collected. A GPRS/Bluetooth based system to send data to a server – Data is sent to the server from battery automatically using GPRS or Bluetooth connection. Enclosure study- safety and cooling of the battery Each battery pack is dependent on mechanical, thermal and environmental factors to perform in its optimal range. Parameters studied for teardown to understand enclosure capability are: –Material grade for thermal performanceGap and vent availability around cells inside pack for flow. Vibration control provisionsShock/impact provisionsWater resistance capability based on type of sealing. Serviceability and other mechanical functions in mind. Enclosure is the critical part of battery pack as it provides the above-mentioned characteristic as well as has to provide spacing for wiring and cooling setup (fluid flow) inside the pack. Enclosure is designed in a way to support increase in battery cells without huge change in enclosure... --- > This is a blog about benchmarking features, BOM and architecture of an electric vehicle charger. This also includes study of all direct costs of the EV charger by zero based costing method. - Published: 2025-05-17 - Modified: 2025-05-26 - URL: https://advancedstructures.in/ev-charger-teardown-cost-driver-comparison/ - Categories: Automotive Product Studies This is a blog about benchmarking features, BOM and architecture of an electric vehicle charger. This also includes study of all direct costs of the EV charger by zero based costing method. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Recently we conducted a teardown for VA/VE exercise on EV Charger from two different OEMs, while doing so we formulated a strategy to reduce the cost of charger PCB used in automotive 2W applications by 11%. At Advanced Structures India we use Engineering Intelligence augmented with a proprietary xcPEP tool to map material, architecture, manufacturing, complexity, and cost in a comprehensive manner. The cost drivers are compared up to the last level of detail & ideas for cost reduction are generated. This blog will focus on our findings while comparing the EV chargers for 2 Vehicles in following areas:Charger’s packaging study & its comparisonComponent complexity in chargers and Component Size Range in PCBCharger & PCB MaterialCost AnalysisComprehensive comparison & cost reduction through xcPEPCompetitor selection is an important step in order to generate large number of ideas as we can have access to industries most cost-effective solutions that can be challenged with your practices. Generally, the cost reduction activities for products done in absolute turn out to be 40% less effective than a comparative study. Charger Packaging Study & Its Comparison Schematic and section views are created while doing the teardown and these views are studied in side-by-side analysis while doing the comparison. Charger A Charger B While comparing both the charger it is observed that the packaging design of chargers are much more complex in Charger A because it’s housing is a 4-piece design compared to 2-piece design in Charger B, which further require a greater number of fasteners (10 more fasteners) for assembly of charger. This affects the manufacturing cost and time. Although the charger B is of slightly higher spec. (Refer Spec Table Below)Also, assembly of harness was observed to be more complex in Charger A when compared to Charger B, In Charger A, a Male and Female connector were provided to connect power chord with charger assembly as compared to Charger B. Increasing the cost of assembly by 6 %. In charger A, smaller heat sink is provided which connect to aluminum housing with help of thermal paste, whereas in Charger B comparatively a very large heat sink (60% larger heat sink compared to Charger-A) is provided for better thermal efficiency. A block and signal diagrams are created for the Charger PCBs for comparison and studying the circuit. Charger A Charger B Even though the charger specification were found similar the overall philosophy of PCB circuit and usage of components were quite different in both chargers. In PCB of Charger A there is bridge rectifier (GBU808) packaged but same in Charger B is managed by using 4 single diodes (IN5408), which costs 40-70% lesser than bridge rectifier. A potentiometer is placed in PCB of charger A unlike charger B, this saved the overall PCB component cost by 1 % for Charger B. 2A 250 VAC slow blow radial fuse is provided in PCB of Charger A at input side only, but in PCB of Charger B it is provided with 2 Fuses one at input and another at output side, reducing fuse cost by 50% for Charger A. A single N channel MOSFET(FHA20N60) is used as a switching device in PCB of charger A where as in PCB of Charger B there is an integrated off line switcher (TO252-262). Component Complexity in Charger and Component Size Range in PCB While studying the complexity of chargers, it is observed that charger A has 55 components compared to 16 components in charger B leading to 70% higher complexity in charger B (except PCB components). Number of components were higher in PCB of Charger A (174 Components) than PCB of Charger-B (152 Components) leading to higher complexity of the circuits, assembly & size of the PCB. Also, while studying component size and component spacing it was observed that in PCB-A, 45% of component size were used in range 0-2 mm while in case of PCB-B, only 39% of component was found in the range of 0-2 mm. PCB - Charger A PCB - Charger B Thumb rule says a lower quantity of component and larger size component’s usage is economical because assembling them on board will require a machine with lesser tolerance and better precision. Similarly on PCB packing components closely again increase the cost of assembly although it decreases the board size. So, based on the basis of this analysis multiple suggestions were made to the client where consideration was to check the feasibility of an increase in component size and spacing. Material used in Charger and PCB On analyzing the material present in both Chargers,... --- > Detailed teardown and BOM analysis of Smart TV 43. Explore LED TV component costs, and manufacturing insights. - Published: 2025-05-17 - Modified: 2025-06-04 - URL: https://advancedstructures.in/xiaomi-smart-led-tv-43-teardown-bom-and-should-costing/ - Categories: Consumer Electronics Product Studies Detailed teardown and BOM analysis of Smart TV 43. Explore LED TV component costs, and manufacturing insights. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Smart LED TV Teardown, Bill of Materials & Should Costing and Analysis Prominent Features of Smart LED TV A comprehensive teardown and benchmarking of the Smart LED TV 43” was conducted, analyzing 43 features, specifications, and product-level details. Highlighted below are some of the standout features: Smart LED TV Display Technology The Smart LED TV 43” has a 4K UHD display with a resolution of 3,840 × 2,160 pixels. The screen supports a wide color gamut, covering 94% of the DCI-P3 spectrum, and displays 1. 07 billion colors. With a refresh rate of 60Hz and MEMC technology up to UHD 60Hz, it ensures smooth visuals. The viewing angle stands at 178° horizontally and vertically, providing consistent picture quality from various positions. Additionally, the TV supports HDR10 and HLG for enhanced dynamic range. Resolution:4K UHD display with 3,840 × 2,160 resolution. Color Gamut:Wide color gamut covering 94% of DCI-P3 spectrumColor Depth:1. 07 billion colors for vivid visuals. Refresh Rate:60Hz refresh rate with MEMC technology Audio Performance of Smart LED TV Equipped with two 15W speakers, the TV delivers a total sound output of 30W. It supports Dolby Audio™, DTS:X, and DTS® Virtual:X sound technologies, offering an immersive audio experience with clear dialogue and rich bass. Sound Output:30W total sound output (2 x 15W speakers). Audio Technology:Dolby Audio™, DTS:X, and DTS® Virtual:X supportSound Quality:Clear dialogue and rich bass. Features of Smart LED TV Operating System:Google TV™ with access to apps like Netflix, Prime Video, and YouTube. Voice Control:Built-in Google Assistant for voice control. Streaming Support:Chromecast and Miracast support for easy streamingApp Store:Google Play Store for downloading apps like Netflix, Prime Video, and YouTube Processing and Storage Features of Smart LED TV Processor: Quad A55 CPU and Mali G52 MP2 GPU for smooth performance Memory and Storage: 2GB RAM and 8GB internal storage and Mali G52 MP2 GPU for smooth performance Bill of Materials (BOM) of Smart LED TV 43” We conducted a detailed teardown of the Smart LED TV 43” to study its components and system architecture. This teardown study involved analyzing data related to various part attributes, enabling a comprehensive understanding of its design and functionality. Smart LED TV Weight Distribution Analysis. Smart TV Weight Distribution Overview: The teardown of the Smart LED TV 43” provided insights into the weight distribution across various assemblies, highlighting the contribution of key components. The television unit itself accounts for 70. 66% of the total weight, comprising key functional elements such as the display panel, PCBs, and power supply. The packaging weight (27. 66%) reflects the necessity of secure transit protection, while accessories and the remote contribute minimally to the overall weight. Major Components Weight Contribution of Smart LED TV Panel Rear: 2280g – Forms a significant portion of the structural weight, providing support and protection. Packaging (Outer Box): 1944g – Essential for transportation safety. Crystal Black Panel: 743g – Major component in the display assembly. Crystal Black Panel Inside Layer: 742g – Works alongside the outer panel to enhance display performance. Manufacturing Category Distribution Analysis of Smart LED TV A detailed teardown and benchmarking study of the Smart LED TV 43” identified various manufacturing categories based on component types and production processes. This analysis helps in understanding the sourcing and fabrication techniques used in its construction. Overview of the Manufacturing Category Distribution of Smart LED TV This category-wise distribution provides insights into the various materials and components used in the manufacturing of the Xiaomi Smart TV 43”. The Mechanical Bought-Out Parts (BOP) (39. 04%) form the largest segment, followed by bolts (19. 25%) and hard consumables (8. 56%). PCBs account for 5. 35%, reflecting the electronic complexity of the device. The combination of moulding, fabrication, and packaging elements highlights the diverse manufacturing techniques used in assembling the television. This structured approach ensures durability, efficient production, and seamless integration of components. Smart LED TV Multi-level BOM (Bill of Materials) Structure After the teardown, we used a Multi-level BOM (Bill of Materials) structure, which provides detailed insights into the main assemblies, their sub-assemblies, and individual components. This approach ensures a comprehensive analysis of the product's design, material composition, and functionality. The BOM (Bill of Materials) structure for the Smart LED TV, with the number of assemblies and their child components, is summarized in the table below: Above image is of xcPEP BOM (Bill of Material) page view Smart TV Teardown and Detailed BOM (Bill of Materials) Analysis Total Assemblies and Components - After teardown, 4 assemblies and 112 components were identified in the Xiaomi Smart TV. Component Parameters: Additionally, 40 BOM (Bill of... --- > This is a blog about benchmarking features, BOM and architecture of an automotive power steering pump. This also includes study of all direct costs of the hydraulic steering pump by zero-based costing method. - Published: 2025-05-17 - Modified: 2025-05-26 - URL: https://advancedstructures.in/lcv-steering-pump-teardown-benchmarking-should-costing/ - Categories: Automotive Product Studies This is a blog about benchmarking features, BOM and architecture of an automotive power steering pump. This also includes study of all direct costs of the hydraulic steering pump by zero-based costing method. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Recently we conducted VA/VE exercise on the Power Steering Pump used for commercial vehicle applications. Engineering insights are generated for study of packaging, integration, features, interface with other subsystems, and more. This blog contains our findings on the Power Steering Pump consisting of:Introduction to Power Steering Pump and its types. Disassembly and feature study of Power Steering Pump. Bill of materials generated from xcPEP. Architecture and layout study of Power Steering Pump. What is a Power Steering Pump? The Power Steering Pump is the heart of the hydraulic steering system. It converts rotational energy supplied by the engine into hydraulic energy. The Pump is driven by the engine via a belt and pulley. The pump contains a set of retractable vanes that spin inside an oval chamber. As the vanes spin, they pull hydraulic fluid from the inlet line at low pressure and force it into the outlet at high pressure. Theory of Operation. All pumps function by creating a partial vacuum at the inlet, which causes atmospheric pressure to force fluid into the pump from the reservoir. The pump then pushes this fluid into the system for use. The fluid is used to power the steering gear. Pump output flow relates to steering gear speed and pumps output pressure relates to steering gear force. Types of Power Steering Pump. Power steering systems date back to 1925 when they were first introduced by the Detroit pump manufacturer Vickers. Today they are standard on most vehicles. Different types of power steering pumps are used to power the steering system. The main difference between the different types of pumps is the design of the fins that move the steering fluid that is inside the pump and expelled through built-up pressure. They are all similar in that they contain a rotor inside the pump housing that spins. There are three different types of pumps used in power steering systems. Vane Power Steering Pump: Vane pumps are the most common type of power steering pumps used. In this type of pump, the rotor is housed in an oval or elliptical-shaped housing where it turns. Vanes fitted to the outside diameter of the rotor sit against the housing walls as the rotor turns. When power steering fluid enters into the vane pump housing it is trapped between the vanes, the housing wall, and the rotor. A subsequent pressure increase causes the fluid to be pumped out of the housing and then through the outlet chambers. Roller Power Steering Pump: In a roller power steering pump, wide V-shaped grooves cut into the side of the rotor allow steel rollers to ride along the inside contour of the pump. The pump is contained in an oval-shaped housing within the pump body. Centrifugal force pushes the rollers to the oval’s outer edge where they trap fluid, similar to the way the vanes catch the fluid in a vane pump. The pressurized fluid is forced out through two outlets in the pump, driving the power steering system. Slipper Power Steering Pump: The slipper power steering pump has a rotor housed in an elliptical-shaped chamber that rotates within the body of the pump. Fitted into wide slots on the rotor are springs that are topped with scrubber-type “slippers. ” The springs keep the slippers in constant contact with the wall of the pump. As fluid enters the pump, pressure is built up and released to drive the power steering system. Power Steering Pump Chosen for the activity. The Power Steering Pump we have chosen for the activity is the Vane Power Steering Pump. This blog will focus on our findings on Power Steering Pump in the following areas:Power steering PumpArchitectureFeature mapping. Sub assembly level teardown. Rotor, Cam Ring, Vanes and otherStructural components. xcPEP’ s role in analysis Architecture mapping In the architecture module of xcPEP, the following are mapped:Product/Sub-system packaging diagram. Product/Sub-system Exploded View. This is mapped for all products & all sub-systems. Once it is created, from the architecture analysis function on xcPEP stats can be generated. 1. Front View Packaging Architecture Representation 2. Back View Packaging Architecture Representation 3. Left Side View Packaging Architecture Representation 4. Bottom View Packaging Architecture Representation 5. Cross Sectional View Representation 6. Exploded View Representation Feature Mapping. In the Feature module of xcPEP, the following are mapped:Feature: Features, USP of the productSpecification: technical/other specs of the product. Information. These parameters are mapped to feature module, and from feature analysis functions ideas are generated. Feature Mapped Type of Steering Pump – The Power Steering Pump is a balanced, positive displacement, sliding... --- > Our engineers tore down a catalytic convertor to study its design, materials and then conducted a zero based costing activity on all parts including rare earth element loading in the substrate. - Published: 2025-05-17 - Modified: 2025-05-26 - URL: https://advancedstructures.in/benchmarking-should-costing-catalytic-converter-substrates-for-manufacturing-cost-and-rare-earth-element-loading/ - Categories: Automotive Product Studies Our engineers tore down a catalytic converter to study its design, materials and then conducted a zero based costing activity on all parts including rare earth element loading in the substrate. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. This blog is about the substrates used in catalytic converters their loading and more specifically focuses on the cerium-based catalytic ceramic substrates. Catalytic converters are crucial emission control devices integrated into vehicle exhaust systems. They employ a combination of catalyst materials to facilitate the conversion of harmful pollutants present in exhaust gases into less harmful substances. Among the various types of catalytic converter substrates available, we have discovered that cerium-based substrates exhibit remarkable durability and efficiency in promoting the desired chemical reactions within the catalytic converter. These cerium-based catalytic ceramic substrates offer several advantages over other substrates. They possess a high oxygen storage capacity, which aids in maintaining optimal catalytic activity. Furthermore, they enhance the catalytic activity itself, leading to more effective pollutant conversion. Additionally, these substrates demonstrate excellent resistance to sulphur, ensuring long-term performance and reduced emissions. Moreover, they exhibit exceptional thermal stability, further contributing to their overall effectiveness in emission reduction. One notable advantage of cerium-based substrates is their cost-effectiveness compared to alternatives like rhodium, palladium, and platinum. The lower cost of cerium makes it an attractive option for catalytic converters, without compromising on performance or environmental benefits. The primary objective of this blog is to present our study on the loading of rare earth metals, specifically cerium, in catalytic converters. We will delve into the methodology we employed to determine the optimal load of cerium in both the core and coating surface of the substrate. Furthermore, we will provide a detailed analysis of the should costing of the cerium-based substrate, shedding light on its economic viability. Construction: The ceramic substrate is designed with a honeycomb-like structure, consisting of numerous small channels or passages. These channels create a large internal surface area, allowing the exhaust gases to flow through the substrate while maximizing the contact with the catalyst. The ceramic substrate is classified into three different types according to wall thickness: Standard (>0. 13mm), thin-wall (0. 10mm), and ultra-thin wall ( --- > This is a blog post about how we've torn down and benchmarked an ADAS radar sensor to study its construction and then conducted a zero-based costing activity on it. - Published: 2025-05-16 - Modified: 2025-05-26 - URL: https://advancedstructures.in/continental-ars-4-b-radar-sensor-teardown-and-should-costing/ - Categories: Automotive Product Studies This is a blog post about how we've torn down and benchmarked an ADAS radar sensor to study its construction and then conducted a zero-based costing activity on it. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Fig No. 1. 1 Antenna Fig No. 1. 2 CONTINENTAL ARS 4-B RADAR SENSOR With the advent of advanced safety features like Adaptive Cruise Control, Emergency Brake Assist, and Forward Collision Warning, the need for Continental ARS 4-B Radar Sensor in cars is increasingly necessary. The Continental ARS 4-B radar sensor is used in a range of vehicles, including Tesla Model 3 & Mercedes Benz E Class. This sensor is mounted to the front center of the car behind the bumper, and it provides critical data to car’s safety systems or ADAS (Advanced Driver Assistance Systems). It has a field of view that covers both short and long-range scans. For short-range scans, it can cover a distance of up to 55 meters with an angle of ±45°. For far-range scans, it can cover distances of up to 120 meters with an angle of ±9° and up to 170 meters with an angle of ±4°. Additionally, the sensor has a field of view in elevation covering +18° for both far and near-range scans. Continental ARS 4-B has its Radio Frequency PCB and Low Frequency PCB separation using an aluminum shielding (see Figure 1. 2). The Radio Frequency PCB contains three receiver (Rx) antennas and two transmitter (Tx) antennas (Ref. Figure 1. 1). The frequency of the Continental ARS 4-B radar sensor ranges around 76-77GHz. The Continental ARS 4-B sensor utilizes FMCW (Frequency Modulated Continuous Wave) technology with rapid ramps to measure the distance and velocity of objects without reflectors. This measurement is achieved in a single cycle, utilizing Doppler’s principle and is performed at real-time scanning rate of 15 scans per second and the data is generated after every 60ms. The sensor is also capable of measuring relative velocities between -400 and +200 km/h. This comprehensive blog offers a thorough analysis of the Continental ARS 4-B radar sensor, covering its features, specifications, packaging construction, PCB architecture, bill of materials, and manufacturing cost. In our teardown lab located in Bangalore, we have diligently gathered and scrutinized more than 5,000 data points concerning this radar sensor, which consists of 23 features and specifications, 9 parts, and over 70 PCB components listed in the bill of materials and Cost BOM. Every single part has been assessed based on an average of 25 parameters according to their respective categories, and a comprehensive should costing analysis has been conducted. Furthermore, we have produced 12 schematic diagrams to comprehend the sensor’s construction and architecture. We have captured over 100 images to explore the component at different teardown stages and to compile the bill of materials. Features of 77GHz Continental ARS 4-B 1. Field of View in Azimuth & Elevation The vehicle’s Short-Range Scan covers a distance of 55 meters and scans angles between ±45°. For Far-Range Scan, the vehicle can travel up to 120 meters while scanning angles between ±9°, and up to 170 meters while scanning angles between ±4°. Additionally, with the installation of Continental ARS 4-B, the vehicle can cover an elevation angle of +18° for both Far and Near range scans, as shown in Figure 1. 3 and 1. 4. Fig No. 1. 3 Illustration of field of view Fig No. 1. 4 Illustration of field of view in Azimuth 2. Object Detection: The Continental ARS 4-B sensor has the ability to detect and measure the radial distance, speed, and azimuth angle of multiple targets concurrently. With the aid of radar technology, this sensor is capable of identifying up to 64 objects within the designated Field of View, as shown in Figure 1. 5. Additionally, the high-resolution object detection capabilities of this sensor allow for the identification of multiple scattering centres (Fig. 1. 6) of objects within the Field of View. Fig No. 1. 5 Objects Detection in the field of view Fig No. 1. 6 Objects Detection with scattering centers per object 3. Future driving path of the vehicle: By detecting and evaluating all objects within its Field of View, the sensor is capable of analyzing the current data collection and estimating the future driving path of the vehicle, as depicted in Figure 1. 7. Fig No. 1. 7 Future Driving Path of the vehicle 4. Adaptive cruise control and emergency brake assist Adaptive Cruise Control: The sensor detects objects within its Field of View and transmits a targeted message output to the Adaptive Cruise Control (a driver-assistance system), as shown in Figure 1. 8. The following are the messages sent by the radar sensor: A message containing a list of all objects detected within the Field of View. A... --- > How to do teardown benchmarking and zero based costing of a home appliance like kitchen chimney. - Published: 2025-05-16 - Modified: 2025-05-26 - URL: https://advancedstructures.in/elica-chimney-efl-s601-benchmarking-teardown-should-costing/ - Categories: Home Appliances Product Studies How to do teardown benchmarking and zero based costing of a home appliance like kitchen chimney. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. A kitchen chimney serves as an essential electronic appliance, diligently working to maintain a clean and nongreasy kitchen environment by effectively eliminating smoke, odours, and oil particles. Chimneys work on a principle that hot air rises above cold air. Hot air from the cooking creates a condition where chimney has to suck all the hot air that consist of smoke, dust and oil. once this is done the hot air goes through a series of filters where it loses oil, dirt and plain smoke at different levels. By the time the hot air reaches the chimney’s exit point, it is just normal hot air being thrown out. All the oil, smoke, dirt has been extracted by the chimney. Exploded View of Elica EFL-S601 HAC VMS ChimneyThe Elica EFL-S601 HAC VMS Chimney represents a significant engineering advancement in kitchen ventilation technology. Designed to address the challenges posed by oil deposits, water vapours, and the efficient extraction of smoke and odours, this chimney integrates several key features to ensure optimal performance and longevity. One feature of the Elica EFL-S601 HAC VMS Chimney is its filter less technology, eliminating the need for traditional filters. This advancement not only streamlines maintenance but also enhances airflow and overall system efficiency. To safeguard the smooth functioning of the motor, it is equipped with a sealed design, effectively preventing the adverse effects of oil deposits and water vapours that commonly occur in kitchen environments. The chimney incorporates a high-quality metal blower system, engineered to efficiently exhaust smoke and odours from the kitchen. This component ensures the removal of airborne contaminants, providing a clean and fresh cooking environment. The Elica EFL-S601 HAC VMS Chimney also boasts motion sensing technology, enabling easy operation with a simple wave of the hand. This touchless feature enhances user convenience, allowing seamless control without the need to physically interact with buttons or switches. We have performed an extensive teardown of the Elica EFL-S601 HAC VMS Chimney, including its packaging, in order to gain a comprehensive understanding of its construction and cost breakdown down to the smallest components. This blog provides a comprehensive examination of the Chimney, encompassing its characteristics, specifications, packaging structure, PCB design, bill of materials, and the manufacturing expenses involved. In our teardown lab located in Bangalore, we have diligently gathered and scrutinized more than 25000 data points for this Kitchen Chimney, the data consists of features, specifications, Architecture, Bill of materials and Costing. Every single part has been assessed based on an average of 35 parameters according to their respective categories, and a comprehensive should costing analysis has been conducted. Features of ELICA KITCHEN CHIMNEY EFL - S601 HAC LTW VMS 1. Filter less Technology Filter less technology in Elica kitchen chimneys represents a significant innovation in the field of kitchen ventilation. Traditionally, kitchen chimneys have relied on filters to trap grease, oil, and other airborne particles. However, these filters require regular cleaning and maintenance, which can be time-consuming and inconvenient for users. Elica’s filter less technology eliminates the need for traditional filters, offering a more efficient and hassle-free solution. metal blower system ensures that the smoke and odour are efficiently exhausted out of the kitchen. Elica Filter less Kitchen hoods are fitted with sealed motor to ensure that oil deposit and water vapour’s does not affect the smooth functioning of the motor. 2. Gesture Control EFL-S601 HAC VMS comes with motion sensing technology that enables easy operation by a simple wave of your hand. Waving hand towards right to turn on the chimney and continue waving to increase the speed. While waving towards left will decrease the speed and finally turns it off. 3. Heat Auto-Clean Technology The Elica chimney uses Heat Auto-Clean technology that makes the use of heating element to get rid of the sticky oil particles inside the chimney and collect it in the oil collector placed right below. To start the heat auto cleaning, press auto clean button for 3 seconds. The chimney will be heated for 9 minutes, then the motor will run in the low speed for 1 minute. Heating Film : The Elica kitchen chimney incorporates a heating film as a key component in its design. The primary purpose of the heating film is to activate the auto clean function of the chimney. When the auto clean button is pressed on the control panel, the heating film is energized, generating heat. This heat is then transferred to the surrounding metal frame. The elevated temperature of the metal frame helps to melt and dissolve the sticky oil particles that may... --- > We benchmarked a DJI Inspire 1 drone to study its design and direct cost. This study also included a detailed zero-based costing exercise of all the drone components. - Published: 2025-05-16 - Modified: 2025-05-26 - URL: https://advancedstructures.in/dji-inspire-1-drone-teardown-and-should-costing/ - Categories: Consumer Electronics Product Studies We benchmarked a DJI Inspire 1 drone to study its design and direct cost. This study also included a detailed zero-based costing exercise of all the drone components. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Prominent Features of DJI Inspire 1 Drone A detailed study on DJI Inspire 1 Drone was conducted where 184 features and 55 specifications/information were mapped, which include the product & subsystem levels of DJI Inspire 1 drone. Some of the prominent features are listed below: Shock Absorber 4 shock absorbers are provided (one for each leg), which consist of a damper (piston) and a spring. This system is used to absorb the force transmitted to the legs of the drone when landing the DJI Inspire drone. The shock absorber unit consists of:PistonSpringRubber SealOil Monocular Camera The vision positioning system in DJI Inspire drone is provided with a monocular camera and two SONAR sensors which assist the DJI Inspire drone when it is being used indoors. A monocular camera system consists of 3 lenses, where the bottom-most lens is the fisheye lens for wide-angle view and the other two lenses are used as relay lenses to project the image onto the eyepiece from the fish eye lens (bottom-most lens) and to invert the image, making it erect. The working altitude range of the Vision positioning system provided in the DJI Inspire drone is 5-500 cm and it works best when operating on non-absorbing surfaces or surfaces with a clear and distinct pattern. Monocular Camera Sensor The monocular camera sensor is provided on the PCB in the Vision Positioning System unit. A CMOS (Complementary metal-oxide-semiconductor) type sensor is provided for image sensing in a monocular camera, these types of sensors are used as they consume 100 times less power than that of CCD (Charge - Coupled Device) and low light sensitivity. GPS Antenna A ceramic type of antenna is provided for this purpose as it is smaller in size and more resistant to environmental noise. GPS is provided in DJI Inspire drone to monitor the current location of the vehicle and communicate with the remote controller. RTH (Return to Home) DJI Inspire drone is provided with a feature that allows the drone to return to the home point (previously set by the user) or to the current location of the remote controller. Below are the three cases for RTH functionality to be activated. Three types of RTH have been provided:Smart RTH– This can be activated using a remote controller or DJI GO APP, this feature is user dependent, and this mode can be activated using the controller. Low Battery RTH– When the battery reaches a critical level DJI Inspire drone is made to land automatically. This feature is triggered when the battery level reaches below a certain point that may affect its landing. Failsafe RTH- DJI Inspire drone returns to the previously set home point when the signal is lost with the remote controller for more than 3 seconds, provided the compass is working. Intelligent Flight Battery System DJI Intelligent Flight Battery System is provided in DJI Inspire drone where the Battery management system unit is integrated within the battery (BMS PCB is provided on top of the battery). The maximum flight time using the standard battery is 18 minutes. Self-Adaptive Landing Gear This feature allows the landing gear to lift automatically when the DJI Inspire drone is 1. 2meters from the ground surface. This feature can be enabled using DJI GO App, it is present under main controller settings. Flight Modes Three flight modes are provided in the DJI Inspire drone which are:P-Mode (Positioning Mode): This mode works best when the GPS signal is strong, three modes are present in P-Mode which will be selected automatically by the DJI Inspire drone. A-Mode (Altitude Mode): In this mode, only a barometer is used for maintaining altitude. Both GPS and Vision Positioning Systems are not activated in this mode. F-Mode (Function Mode): IOC (Intelligent Orientation Control) mode is activated in this mode. This mode is mostly used for taking photos where the direction of the nose of the drone is not necessarily considered the forward direction of the drone. Servo Motor Servo motor is used for the motion of boom when DJI Inspire drone is switched between different modes. Servo motor is used as a linear or rotatory actuator, here the motor meshes with a rack and pinion gear for linear motion of boom. Gear reduction is used inside the servo motor for increasing the torque. 4 gears are provided in the Servo motor out of which two are used for gear reduction. Propeller Direction The Propeller blades are made to rotate in a specific direction to balance DJI Inspire drone when it is in flight. Two diagonal blades are... --- > This is a blog about benchmarking features, BOM, architecture and zero-based costing of an automotive starter motor. - Published: 2025-05-16 - Modified: 2025-05-26 - URL: https://advancedstructures.in/starter-motor-teardown-should-costing-and-feature-study/ - Categories: Automotive Product Studies This is a blog about benchmarking features, BOM, architecture and zero-based costing of an automotive starter motor. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Recently we conducted VA/VE exercise on the starter motor used for commercial vehicle application. We at Advanced Structures India use Engineering Intelligence and xcPEP to map data which includes material information, architecture and layout study, manufacturing process and complexity data. This blog contains our findings on starter motor consisting of: Introduction to starter motor and its types. Features and specifications mapped in starter motor. Bill of materials generated from xcPEP. Architecture and layout study of starter motor. Introduction to starter motor and its types Starter motor: A starter motor is an electric motor designed to initiate the operation of an internal combustion engine. The pinion gear meshes with the flywheel and rotates it when the key is turned ON and disengages when the engine starts to run by itself. Different types of starter motors used: Types based on Gear reduction methods: Direct Drive Electric Starter MotorGear Reduction Type Starter Motor Types based on armature: Permanent Magnet armature typeField Coil armature typeThe motor considered in this activity is of gear reduction type where planetary gear set is used for torque multiplication since the size of the flywheel is large and higher torque is required to rotate it. The starter motor used for study is observed to be a permanent magnet armature type as it is provided with permanent magnets which acts as a stator and rotates the rotor made up of electromagnets. Features mapped in starter motor Features are mapped using xcPEP tool. The features are divided into two categories:Product level features. Part level features. Product level features: Product level features are data which are mapped by considering the product as whole system. Some of the product level features mapped are: Breather or pressure vent: Breather made up of rubber is present to regulate the pressure built-up inside the motor by releasing excess pressure to the atmosphere. Damper provided between solenoid and motor casing: Rubber damper is used between solenoid and motor casing to reduce transfer of vibrations from motor to solenoid during the meshing of pinion gear with flywheel. Ground Provision: Metal bracket acts as a ground for this starter motor which is mounted to the backplate of the motor casing using a M6 hex head bolt and a washer. Part level features: These features are mapped by considering individual parts of the starter motor as a separate system which gives us a proper understanding of all the individual parts present in the starter motor. Some of the part level features are: Stator type: Four permanent magnets which acts as a stator are glued and separated using clips inside the permanent magnet casing which helps in rotating the rotor made up of electromagnets. Gear Reduction type: Commercial vehicles require a higher torque due to the size of its flywheel when compared with passenger vehicles hence the planetary gear set is used for gear reduction. Here the input is given through sun gear and output is taken from the carrier or planetary gears. Spline gear: Longitudinal and rotational motion is observed while the pinion gear moves along the shaft which is possible due to the spline gear provided on the planetary carrier output shaft, which also helps in better meshing of the pinion gear with Flywheel. Specification mapped in starter motor Specifications are categorised into two types: Product level specification Part level specification Some of the product level Some of the product level specifications are mentioned below: Some of the part level specifications are mentioned below: Bill of materials generated from xcPEP A product level BOM is first created on xcPEP which outlines the basic data of the product as an entity. The details mapped here are weight, box dimensions, supplier data, mounting method and mounting locations. Orthographic and isometric views of part and any information present on the part(information stickers)are captured and updated. Once the part level data entry is done, the part is tore down into different sub-assemblies or sub-systems based on its functionality. The subsystem list is represented in hierarchical structure with part number at the top of the list. After mapping all the product data, the product is further divided into sub systems for which the same data as the product are also mapped. The sub system of the product are further torn down to last level and all the individual parts are created under their respective sub systems. The created last level parts are then mapped with the details like box dimensions, Materials, Surface coating and thickness, Supplier data, Manufacturing process(Primary, Secondary and tertiary manufacturing process) and dependencies. Architectural Study of Starter Motor... --- > This is a blog about benchmarking features, BOM and architecture of an automotive PCB. This also includes study of all direct costs of the PCB by zero based costing method. - Published: 2025-05-16 - Modified: 2025-05-26 - URL: https://advancedstructures.in/pcb-teardown-benchmarking-cost-reduction-insights/ - Categories: Consumer Electronics Product Studies This is a blog about benchmarking features, BOM and architecture of an automotive PCB. This also includes study of all direct costs of the PCB by zero based costing method. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. PCBs make up over 15% of the Bill of Materials (BOM) cost in electric vehicles (EVs). Considering the recent fluctuations in the cost of electronic components, it is crucial to focus on studying PCBs. This blog aims to provide an in-depth understanding of the PCB teardown and benchmarking process and how it can generate insights for cost reduction and target setting. Our proprietary SaaS platform, xcPEP, ensures high-quality data mapping with zero errors and analyses them to determine target costs for PCBs in EVs. PCB teardown and benchmarking involve a detailed analysis of the components, materials, and manufacturing processes used in a PCB. This information is used to compare and improve the design and quality of PCBs. Through this blog, we will delve into the PCB teardown and benchmarking process, methods used, and the potential outcomes that can be achieved through these analyses. At ASI, we employ a variety of activities to ensure accurate and comprehensive benchmarking of PCBs which includes the following:Generating the Bill of Materials (BOM) for the PCBMapping the data for electronic child partsCreating an architecture diagram for the PCBIdentifying the layers of the PCB. Determining the cost of electronic child parts. Calculating the process costs involved in PCB manufacturingGenerating ideas for PCB cost reductionConducting should costing for the PCB boardConducting should costing for the PCB transformerAnalysing the utilization of the PCB areaIn this technical blog, we will discuss deeper into each of these activities and how they contribute to the benchmarking process. PCB Teardown During teardown process, PCB is systematically disassembled and inspected to identify the hierarchy of the electronic child parts and map their respective connections. This information is then used to create an accurate architecture diagram for the PCB. In addition, multiple pictures are taken at different stages of the teardown process to provide a visual record of the board’s components and their interconnectivity. By performing a detailed teardown of the PCB, we can gain insights into the quality of the board’s design and manufacturing and identify opportunities for improvement. This information is crucial for benchmarking the performance of the PCB and ensuring its optimal functionality in the automotive component. Types of PCBs Single Sided: PCBs with components on one side only. Double Sided: PCBs with components on both sides. Multi Layered: PCBs with multiple layers of copper and insulating material sandwiched together. Aluminium Base: PCBs with a base layer made of Aluminium, used for heat dissipation. Flexible: PCBs with a flexible base material, used in applications with tight or irregular spaces. Ceramic Base: PCBs with a base material made of ceramic, used for high-temperature applications. High Frequency: PCBs designed to operate at high frequencies, with specialized materials and construction techniques to minimize signal loss and interference. Equipment used for PCB’s study During the teardown of Printed Circuit Boards (PCBs) to accurately assess Electronic Child Parts, the use of specialized equipment is crucial. The LCR meter, microscope, and hot gun are among the commonly used equipment in this process. The LCR meter provides inductance, capacitance, and resistance measurements of the PCB components, allowing for the identification of their characteristics and value of capacitance, inductance of the child part. The microscope is used to identify small electronic child parts. To remove Electronic Child Parts like transformer, Choke coil inductor from PCB, a desoldering pump or hot air rework station is typically used. These tools utilize heat and suction to remove the parts while minimizing the risk of damage to the surrounding components and PCB traces. By utilizing specialized equipment during PCB teardown, accurate assessment of Electronic Child Parts can be achieved, leading to a more thorough understanding of the PCB’s. PCB BOM When mapping BOM parameters for a Printed Circuit Board (PCB), it is important to consider several key factors. These parameters include:Description: This parameter provides detailed information about the component, including its purpose and specifications. Quantity: This parameter indicates the number of components present on the PCB. Aluminium Base: PCBs with a base layer made of Aluminium, used for heat dissipation. Image: This parameter includes a child part image, allowing for easy identification of the component. Location of Component: This parameter defines the side of the PCB where the component is located (top or bottom). Type: This parameter identifies whether the component is surface mount (SMD) or through-hole (THD). Component Size: This parameter specifies the dimensions of the component, such as the size of resistors or capacitors. Component Type: This parameter identifies whether the component is active (such as transistors) or passive (such as resistors and capacitors). MFR: This parameter identifies... --- > This is a blog about benchmarking features, BOM and architecture of an electric vehicle motor controller unit MCU. This also includes study of all direct costs of the MCU by zero based costing method. - Published: 2025-05-15 - Modified: 2025-05-26 - URL: https://advancedstructures.in/motor-controller-teardown-should-costing-and-cost-driver-comparison/ - Categories: Automotive Product Studies This is a blog about benchmarking features, BOM and architecture of an electric vehicle motor controller unit MCU. This also includes study of all direct costs of the MCU by zero based costing method. Disclaimer This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing. Recently we conducted a teardown for VA/VE exercise on 2W Controller from two different OEMs, while doing so we formulated a strategy to reduce the cost of controller by 7%. At Advanced Structures India we use Engineering Intelligence augmented with proprietary xcPEP tool to map material, architecture, manufacturing, complexity and cost in a comprehensive manner. The cost drivers are compared up to the last level of detail & ideas for cost reduction are generated. This blog will focus on our findings while comparing the EV Controller for 2 Vehicles in following areas:Controller’s packaging study & its comparisonComponent complexity in Controller and Component Size Range in PCBCost AnalysisComprehensive comparison & cost reduction through xcPEPCompetitor selection is an important step in order to generate large number of ideas as we can have access to industries most cost-effective solutions that can be challenged with your practices. Generally, the cost reduction activities for products done in absolute turn out to be 40% less effective than a comparative study. Controller Packaging Study & Its Comparison Schematic are created while doing the teardown and these views are studied in side-by-side analysis while doing the comparison. While comparing both the Controller it is observed that the packaging design of Controller are much more complex in Controller A, i. e. , Controller A’s housing is a 3-piece design with higher thickness value (by 0. 8 mm) compared to 2-piece design in Controller B resulting in high housing weight (more by 18%), also because of 3-piece design, Controller A requires a greater number of fasteners (more by 4) for assembling it. This affects the manufacturing cost and time. Although the Controller B is of slightly higher spec. (Refer Spec Table Below)Also, assembly of harness was observed to be more complex in Controller A when compared to Controller B. Also in Controller A, Female’s connector was provided to for further connection which is available less in number in controller B. Increasing the cost of assembly by 6 %. In Controller A, the heat sink provided is of more thickness (by 1. 8 mm) in comparison to Controller B heat sink. Heat is attached to aluminium housing with help of thermal paste. A block and signal diagrams are created for the PCBs for comparison and studying the circuit. Controller A Controller BEven though the Controller specification were found to be nearly similar the overall philosophy of PCB circuit and usage of components were quite different. Controller B is provided with 3 extra ICs a 3 input NOR gate, hex inverter and quad 2 input and gate. These ICs are not observed to be present in Controller A. In Controller B function for cruise control and reverse were not observed. Component Complexity in Controller and Component Size Range in PCB While studying the complexity of Controller, it is observed that Controller A has 52 components compared to 23 components in Controller B leading to 62% higher complexity in Controller B (except PCB components). Number of components were higher in PCB of Controller A (161 Components) than PCB of Controller-B (138 Components) leading to higher complexity of the circuits, assembly & size of the PCB. Also, while studying component size and component spacing it was observed that in PCB of Controller-A, 62% of component size were used in range 0-2 mm while in case of PCB of Controller-B, only 50% of component was found in the range of 0-2 mm. PCB – Controller A PCB – Controller BThumb rule says a lower quantity of component and larger size component’s usage is economical because assembling them on board will require a machine with lesser tolerance and better precision. Similarly on PCB packing components closely again increase the cost of assembly although it decreases the board size. So, based on the basis of this analysis multiple suggestions were made to the client where consideration was to check the feasibility of an increase in component size and spacing. Material used in Controller and PCB Analysing the material present in both the Controller, it is observed that an extruded aluminium casing present in Controller A is thicker in comparison to Controller B (by 0. 8 mm). Which results in lower cost of Controller casing in Controller B by 20%. Also, steel weight observed to be higher in Controller A, as two steel plates are provided to close the aluminium casing at the ends, where in Controller B the housing only is a box type structure where just one plate is provided at the end which required to close it. This result in higher assembly... --- ---