GuidesBuilt for the Real World: A Modern Alternative to Legacy Should Costing Software

Built for the Real World: A Modern Alternative to Legacy Should Costing Software

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.

Legacy parametric CAD based software prioritises CAD based automated black box costing for quick and inaccurate cost estimates.

By tailoring itself to your specific suppliers, locations, norms, and cost models, xcPEP creates a custom cost template that enables reliable and scalable cost estimation for future products.

5% error in cost calculation leads to 50% error on EBIDTA level.

xcPEP

Should Costing Software

xcPROC

Should Cost Database for Should Costing
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The Raw Material Database contains structured data for a wide range of materials used in manufacturing. Each entry includes material grade, sub-grade, initial shape, density, and cost per unit, along with the corresponding currency. This data allows cost models to reflect real-world sourcing conditions and material usage. It is primarily used in costing, alternate material evaluations, and benchmarking within xcPEP. All values are regularly updated to reflect region-specific sourcing and are maintained by ASI’s internal data research team.
The Machine Database contains structured cost parameters for manufacturing equipment across machining, forming, molding, and fabrication operations. Each machine entry includes brand, operation type, capital and rental costs, installation assumptions, and utility consumption. It also factors in productivity variables such as feed rate, uptime, and life, enabling precise calculation of the machine hour rate (MHR). This MHR serves as a foundational input in xcPEP for estimating operation-wise part costs and comparing routing options. The data is used in operation-level routing analysis within xcPEP and allows users to compare machine options across geography, process efficiency, and cost.
The Operations Database in xcPROC stores cost and rate data for standard manufacturing processes such as machining, welding, coating, heat treatment, and forming. Each operation is linked to relevant parameters like process type, cost unit, and applicable materials or geometries. Unit rates are recorded in engineering-relevant formats such as INR per square meter or INR per kilogram, enabling seamless integration with routing logic in xcPEP. This database supports accurate process selection, supplier comparison, and plant-level cost simulation within should-cost models.
The Labour Database in xcPROC provides region-wise labour hour rates essential for calculating accurate manufacturing costs. It includes detailed breakdowns for skilled, semi-skilled, and unskilled labour, covering parameters such as minimum wages, allowances, perks, and total hourly rates. Categorized by industry and process type, this database helps ensure cost models reflect real workforce costs instead of assumptions. It plays a critical role in should-costing exercises, especially in labour-intensive operations like assembly, casting, and fabrication.
The Tools Database in xcPROC captures tool-level information critical for operations such as assembly, machining, and forming. Each entry includes the tool’s specifications, supplier, material, and category—along with cost and usage life data. This enables tool depreciation to be factored into should-cost models where tooling is a cost driver. The database supports accurate evaluation of part-level tooling costs, especially in cases involving high-volume or custom tooling