Overview
Project Dashboard
Live summary. All metrics update automatically as you fill each section.
Total Capex
--
Rs. Indicative
Payback ⓘ
--
Months · Capex ÷ Monthly Saving
IRR ⓘ
--
% per annum · Must exceed loan rate
Avg DSCR ⓘ
--
7-Year Avg · NCA ÷ Annual EMI · Min 1.5x
Module Completion
0%
PCB Analysis
0%
Plant Design
0%
Financials
0%
Infrastructure
0%
Documentation
Benchmark Comparison
SMT Line Utilisation
--
Industry: 60-75%
Payback Period
--
Target: <36 months
IRR vs Loan Rate
--
Must exceed 11.5%
Average DSCR
--
Bank min: 1.5x
Break-Even % of Cap
--
Safe: <70%
Risk Register
Complete inputs to generate automatic risk assessment.
▶ Strategic Advantages — In-House vs EMS Outsourcing
Key reasons to bring PCB assembly in-house
📈 Cost Savings
Assembly cost per board drops to actual labour + consumable cost — eliminating EMS vendor margin of 25–40% charged on top of their own cost.
🔒 IP & Design Confidentiality
PCB designs, BOM, firmware and test procedures stay within the company. EMS vendors handle multiple clients — in-house eliminates all IP leakage risk.
⚡ Faster Turnaround
EMS batch scheduling adds 2–6 weeks of lead time. In-house assembly produces boards on demand — same day or next day for urgent requirements.
Sensitivity Analysis
Volume Change 0%
Electricity Rate Change 0%
Outsource Cost Change 0%
Adjusted Results
Annual Saving
--
Payback
--
IRR
--
NPV
--
Section 01
Project Details
Client and engagement information. Appears on all reports and presentations.
Client Information
Project Scope
Section 01B
Scope of Work
Define process flow for each PCB. Tick a stage to activate it — a popup asks about special processes before or after. Click Apply Scope when done.
0
Factory Line Configuration
Define how many SMT lines this factory has (1–15). Each line is independent — its own machines, PCBs, products and costs.
Max 15 lines. Each line is fully independent.
Stage Activated
Add a special process around this stage?
Add Special / Custom Process
KW and Capex flow to Infrastructure section automatically.
Process Flow
Select PCB
LEGEND:
Process
Inspection
Decision/QA
Input/Output
Offline/Delay
Start/End
Ready to continue?
Pushes all scope selections to PCB Profile, SMT, THT, Infrastructure and Manpower sections.
Section 02
PCB Profile
Define each PCB type. Physical dimensions, component mix, and costs. Data flows automatically to SMT, THT, Cost Per PCB and Finance sections.
PCB Types 0 PCBs
Section 03
Infrastructure & Capex
Equipment costs and power consumption. Total KVA auto-calculated. DG set recommended automatically. All costs flow to Finance and Cost Per PCB.
Floor Area
Total area: -- sq ft
💱 Currency Exchange Rates (update before recalculating capex)
e.g. 94.28 on 06-May-2026
e.g. 155.92 on 06-May-2026
e.g. 0.85 on 06-May-2026
📊 Derived rates (auto):
JPY → INR: --
EUR → INR: --
JPY → USD: --
Equipment Prices in Foreign Currency → Auto-converted to INR Capex
| # | Equipment | Cat. | Currency | Foreign Price | Qty | Power (KW) | KW × Qty | INR Total (auto) | DDU (USD) | INR incl. DDU |
|---|---|---|---|---|---|---|---|---|---|---|
| Total Foreign Equipment (INR) | -- KW | -- | -- | -- | ||||||
Enter rates above — INR values update automatically. These flow into equipment capex fields.
Additional Equipment
Add any equipment required for this client engagement — barcode marker, rework station, conformal coating, testing chamber, or anything else. Select which table it belongs to.
THT Flip Fixture Cost
One per line. Insert all comps, fit cover, flip once, solder all.
Electrical Load Summary — Complete [Auto-Calculated]
| Load Source | KW | Formula / Basis |
|---|---|---|
| SMT Equipment | -- | Sum of all SMT machine KW x qty |
| THT Equipment | -- | Sum of all THT machine KW x qty |
| AC System | -- | AC Tons x 1.2 KW/ton |
| LED Lighting | -- | Panels x 36W = Panels x 0.036 KW |
| Compressor | -- | HP x 0.746 KW/HP |
| Total Connected Load | -- | Sum of all loads above |
Typical 0.85 for industrial
20% for ture expansion
Complete equipment entries to see total load.
THT Zone Load — Night Shift (Shifts 2 & 3)
When THT runs 2 or 3 shifts, only the THT zone stays powered. Enter the THT area sub-load below — used for accurate electricity cost in Cost Per PCB.
AC for THT area only
Lighting for THT area only
Compressor during THT only
Enter THT zone loads above to calculate night shift electricity cost.
Civil & Utility Costs [Area Auto-Calculated]
Installed: Rs.120-200/sqft
With reflow heat: 150 sqft/ton
For depreciation calculation
24hr basis — hover for formula
Total linear feet of all partition walls
Modular partition Rs.180-350/rft
8-10 per building (IS 3043)
Typical Rs.8,000-12,000 each
300 lux = SMT (IPC-7711 rec.)
Standard 36W panel = 4000 lm
DG Set & Compressor
DG Efficiency Derating
A new DG set at 100% capacity degrades to ~85% with proper AMC and ~70% without maintenance after 5-6 years. Size accordingly.
Future Expansion Plan
e.g. 4 if planning 4 more lines
PEPC Recommendation [Auto-Calculated]
Current Load Requirement
--
Without derating
PEPC Recommends (with derating)
--
Next standard size above derated KVA
Future Expansion Size
--
If expansion plan materialises
Client Decision — Select DG Set to Purchase
PEPC recommendation is pre-selected. Client can override based on their future plan or budget. All calculations update automatically.
Air Compressor
Total Capex Summary [Auto-Calculated]
SLM: 15yr life = 6.67%
24hr basis — hover for formula
Total Project Capex: --
Depreciation Calculation [Auto — Customer-Facing]
| Item | Formula | Value |
|---|---|---|
| Equipment + Civil Capex | As per Infrastructure section | -- |
| Depreciation Method | Straight Line Method (SLM) | SLM |
| Useful Life | As per Companies Act 2013, Schedule II | 15 years |
| Depreciation Rate | 100% / Useful Life | 6.67% p.a. |
| Annual Depreciation | Capex x Rate | -- |
| Monthly Hours (24hr basis) | Working Days x 24 hrs/day (building & asset 24hrs) | -- |
| Depreciation per Hour | Annual Depr. / Annual Hours | -- |
| Total Floor Area | SMT + THT + Testing + Store | -- |
| Rent Rate | As entered | -- |
| Monthly Rent | Area x Rent Rate | -- |
| Monthly Hours (24hr basis) | Working Days x 24 hrs (rent runs 24hrs/day) | -- |
| Rent per Hour | Monthly Rent / Monthly Hours | -- |
Section 04
SMT Line Capacity
CPH weighted by component type. BGA and fine pitch pin counts used for accurate pad calculation. Cycle time per board shown.
SMT Line:
Pick & Place Machines
| # | Brand | Model | Type | Rated CPH | Actual % | Actual CPH | |
|---|---|---|---|---|---|---|---|
| Total Actual CPH | 0 | ||||||
Component Speed Factors
Production Mode
SMT Capacity Results [Auto from PCB Profile]
Effective CPH Available
--
CPH @ OEE
CPH Required
--
All PCB types
Line Utilisation
--
% of capacity
| PCB / Option | Pass | Std | FP | BGA | Lg | Pads | Speed | CPH Req | Cycle(s) | Brd/Hr | Brd/Shift | Brd/Month | Days | Util% |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Enter PCB data in Section 2 | ||||||||||||||
Section 05
Through-Hole Assembly Capacity
THT totals auto-filled from PCB Profile. Break down by component type. Balance must match PCB Profile total. Custom components with editable pin counts.
THT Line:
Soldering Method Selection Matrix
Select one primary soldering method per PCB side. Tick Touch-Up if a manual rework station is needed alongside the primary process.
Pre-filled from PCB Profile — override here as needed.
| PCB / Side | Wave Soldering | Hand Soldering | Selective Soldering | Touch-Up Station | Touch-Up Cycle (s/board) |
|---|---|---|---|---|---|
| Add PCBs with THT in PCB Profile first. | |||||
Component Breakdown Matrix
Totals must match PCB Profile THT count per PCB side
| Component Type | Insert(s) | Joints |
|---|---|---|
| Add PCBs with THT in PCB Profile first. | ||
THT Capacity Summary
Operators Required / Shift = number of human operators needed per shift to produce the monthly volume target for that PCB type, based on cycle time and available hours.
| PCB / Option | THT A/B | Stuff(s) | Method A/B | QA(s) | Cycle(s) | Brd/Hr | Takt(s) | Operators | Days | Match? |
|---|---|---|---|---|---|---|---|---|---|---|
| Select THT scenarios above | ||||||||||
Consumables Matrix — All PCBs
Auto-calculated from PCB Profile. Edit unit costs below.
| Consumable | Unit | Cost/Unit (Rs.) | ||
|---|---|---|---|---|
| Add PCBs in PCB Profile first. | ||||
Pre-Heat Electricity & Nitrogen Costs
Pre-Heat Electricity — Beyond Production Hours
Wave solder switches on 4 hrs before production. Reflow switches on 1 hr before. This electricity is a real cost not captured in shift-hours calculation.
Machine on before production starts
Reflow reaches temp faster
Default OFF — enable only for Class 3 / high-reliability applications
Nitrogen not enabled. For standard BESS PCB assembly (Class 2) nitrogen is not required.
Complete inputs above to see total wave solder consumable cost per board.
Section 06
Manpower Planning
Three categories. Cat1+2 feed Cost Per PCB. Cat3 feeds Finance P&L only.
Category 1 — Direct Production [feeds Cost Per PCB]
| Role | Process | Qty | Shifts | Salary/Month (Rs.) | Monthly (Rs.) | Per Shift (Rs.) |
|---|---|---|---|---|---|---|
| Category 1 Total | -- | -- | ||||
Category 2 — Quality and Engineering [feeds Cost Per PCB as overhead]
| Role | Function | Qty | Shifts | Salary/Month (Rs.) | Monthly (Rs.) | Per Shift (Rs.) |
|---|---|---|---|---|---|---|
| Category 2 Total | -- | -- | ||||
Category 3 — Administration and Management [feeds Finance P&L only — NOT Cost Per PCB]
| Role | Function | Qty | Salary/Month (Rs.) | Monthly (Rs.) |
|---|---|---|---|---|
| Category 3 Total | -- | |||
Summary
Cat1 Production
--
-> Cost Per PCB
Cat2 Quality/Engg
--
-> Cost Per PCB
Cat3 Admin/Mgmt
--
-> Finance P&L
Grand Total
--
Rs./month
Section 06A
Facility Layout Plan
Conceptual ground floor layout — Newen Systems EMS Facility. All dimensions indicative. Final drawings by appointed architect.
Newen Systems — EMS Facility Floor Plan
Site Width: 340 ft (103 m) | Building: 300 × 310 ft | Rev 2 · May 2026
Upload your floor plan to replace this indicative layout
📦 Production Zones
SMT Line 100×40 ft
THT Stuffing 100×40 ft
Mech Assembly 100×40 ft
Testing & Box Assy 80×40 ft
THT Stuffing 100×40 ft
Mech Assembly 100×40 ft
Testing & Box Assy 80×40 ft
🏢 Front Office
Reception 30×20 ft
Conference Rooms (×2)
HR & Admin 15×20 ft
Canteen 30×15 ft
Conference Rooms (×2)
HR & Admin 15×20 ft
Canteen 30×15 ft
🔬 Engineering Hall
R&D Zone 30×20 ft
NPD Zone 20×20 ft
Product Engineering
Quality / Process Eng.
NPD Zone 20×20 ft
Product Engineering
Quality / Process Eng.
🏗️ Utilities
Generator + Compressor
LT Panel Room 20×10 ft
UPS / HVAC
Dispatch Bay 20×30 ft
LT Panel Room 20×10 ft
UPS / HVAC
Dispatch Bay 20×30 ft
Section 07
Cost Per PCB — Activity Based Costing
Shared line costs allocated proportionally by line time. Each column is one PCB type. Read down the rows — every cost head is shown for all PCBs side by side. Professional costing sheet format.
Rate Inputs — Apply to All PCBs
Blended incl. DG set
SAC305 lead-free
Spares, oils, nozzles
Stencil rolls + IPA wipes
At 98% FPY
Min. Rs.8,000–10,000 market
Shutdown+Prog+Pilot x 1.15
Loctite 3900 acrylic default
50µ nominal / 75µ max
Default: both sides
Selective machine overspray
Combined Summary — All PCB Types
Wtd Avg In-House/PCB
--
Wtd Avg Outsource/PCB
--
Total Monthly Saving
--
Annual Saving Year 1
--
% Cost Reduction
--
Simple Payback
--
SMT Line Utilisation
--
Section 08
Production Planning & Mapping
Target calculator for each process: enter target days, press Add to generate resource options. Select a row to lock it in. The Gantt updates automatically. Same sheet used for planning and customer presentation.
Global Settings
Effective target: 19.5d
🔵 SMT — Pick & Place
🔴 THT — Through-Hole Assembly
🟢 ICT — In-Circuit Test
🟡 Functional Test
Select number of test stations:
🟦 Packing
Lock selections → update Gantt, Manpower & Finance
Live Production Timeline
Calculating...
—
Impact vs Base
How to use:
1. Enter target days for each process → press + Add
2. Multiple rows appear — one per scenario
3. Press Select on the row that fits
4. Gantt updates instantly
5. Press Accept & Apply to lock in
1. Enter target days for each process → press + Add
2. Multiple rows appear — one per scenario
3. Press Select on the row that fits
4. Gantt updates instantly
5. Press Accept & Apply to lock in
Planning — Advanced
Real-Time Line Simulation
Parallel/overlapping process flow. Each process starts as soon as the trigger batch arrives from the previous stage — operators never sit idle. Set lags, trigger batches, and per-day exceptions (overtime or stoppages). Base shift hours are read automatically from the Timing sheet.
RAW simulation — reads live from SMT/THT/ICT capacity sheets
Process Configuration — Toggle Active, set lag & trigger batch. Base hrs from Timing sheet.
| Process | Base Hrs/Shift | Shifts/Day | Lag (hrs) | Trigger Batch | Active |
|---|
Day-by-Day Exceptions — Leave blank = normal. Click cell to set Overtime or Stopped.
Overtime
Stopped
Effective Total Days
—
Sequential sum: —
Warnings
Run simulation to see analysis.
How to use:
1. Check active processes & set lags
2. Set working days → Build Grid
3. Click cells for Overtime / Stopped
4. Press ▶ Run Simulation (always visible here)
5. Gantt appears below ↓
6. Print or Add to PPT
1. Check active processes & set lags
2. Set working days → Build Grid
3. Click cells for Overtime / Stopped
4. Press ▶ Run Simulation (always visible here)
5. Gantt appears below ↓
6. Print or Add to PPT
Parallel Production Gantt — RAW Simulation
SMT
THT
ICT
Func
Mech
BoxFunc
Burn-in
Pack
Stopped
Overtime
Press ▶ Run Simulation on the right panel to generate the Gantt chart.
Section 08
Finance Calculator
Capex auto-filled from Infrastructure. In-house cost auto-filled from Cost Per PCB. Outsource cost auto-calculated from PCB Profile. Only loan parameters need manual entry.
Auto-Filled Inputs
Loan & Growth Parameters [Manual Entry]
Bank min: 25-30%
Working Capital
Bill of Material Cost per PCB — enter component cost per board (excludes assembly labour)
Add PCBs in PCB Profile first.
Total Monthly BOM Cost
--
ⓘ BOM cost is included in processing cost base for all WC rows below. Leave at 0 if Newen supplies components on consignment (job-work model).
Raw Material Holding (days)
--
WIP (days)
--
Finished Goods (days)
--
Debtors / Receivables (days)
--
Creditors / Payables (days)
--
Net Working Capital
--
EMI & Loan Structure [Auto]
Monthly EMI
--
Rs. / month
Annual Debt Service
--
Rs. / year
D/E Ratio
--
Must be <= 3:1
Bank Schemes: SIDBI (up to Rs.25Cr, 9-11.5%) | SBI MSME (up to Rs.10Cr, 10.5-12%) | CGTMSE Collateral-free (up to Rs.2Cr) | PMEGP Subsidy (15-35%) | MUDRA Tarun (Rs.10L)
Section 09
DSCR & 10-Year ROI
All 7 ROI types. 10-year P&L projection. Bank credit appraisal format.
10-Year Projections
| P&L Item | Yr 1 | Yr 2 | Yr 3 | Yr 4 | Yr 5 | Yr 6 | Yr 7 | Yr 8 | Yr 9 | Yr 10 |
|---|---|---|---|---|---|---|---|---|---|---|
| Complete Finance section | ||||||||||
All 7 ROI Metrics
| # | Metric | Formula | Year 1 | Year 3 | Year 5 | Year 10 | Status |
|---|---|---|---|---|---|---|---|
| Complete Finance section | |||||||
Section 10
Subsidies & Incentives
Central & Gujarat schemes. Tick to apply — DSCR, IRR, payback and NPV update automatically.
Tick applicable schemes — all metrics update automatically
Capital subsidies reduce net capex & loan. Annual benefits add to NCA. Both improve DSCR, IRR and payback.
Gross capex
--
Before subsidies
Capital subsidy
Rs.0
One-time deduction
Annual benefit
Rs.0
Adds to NCA/yr
DSCR with subsidies
--
vs base --
🏠 Central Government — PLI / Electronics Component Manufacturing Scheme 2025
🏭 State — Gujarat Electronics Policy 2022–28 & Aatmanirbhar Gujarat 2022–27
Stacking: PLI/ECMS (Central): 25% of plant & machinery cost. Gujarat GECMS-2025: 100% top-up = same Rs. amount as Central on same capex base. Net result: 25% + 25% = 50% of machinery cost recovered from government. Interest, power, EPF and SGST all apply to different cost heads and fully stack. | Eligibility: Requires MSME/Udyam registration. Disbursements subject to CA-certified milestone verification.
EMS Revenue
Spare Capacity — EMS Revenue Estimate
Assembly revenue from spare SMT capacity. Flows into DSCR, IRR and payback automatically.
Rate Parameters
Your cost
Your cost
You charge client
You charge client
Avg assumption
Month from commissioning (e.g. 4 = starts in Month 4)
⚠️ Important: EMS revenue will be zero for the first 0 months after commissioning.
DSCR, IRR, Payback and NPV are all adjusted to reflect this delay.
Set to 1 if EMS starts immediately from Day 1.
DSCR, IRR, Payback and NPV are all adjusted to reflect this delay.
Set to 1 if EMS starts immediately from Day 1.
EMS boards/month
--
Gross revenue/month
--
Profit/month (sell−cost)
--
Annual profit (post-tax)
--
| PCB name | Vol/mo | SMT comp | THT comp | Rs./board | Type | Monthly Rs. |
|---|---|---|---|---|---|---|
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| Total (EMS only) | -- | -- | -- | -- | -- | -- |
EMS profit (selling price minus cost price) flows into DSCR, IRR and payback automatically.
SMT Line Utilisation
Newen:--%
+ EMS:--%
= Total:--%
Section 10
Equipment Vendor Scoring
Weighted scoring matrix. Recommended vendor price auto-updates Infrastructure capex.
P&P Machine Evaluation
Vendor A
Vendor B
Vendor C
| Criterion | Weight % | Score A (1-5) | Score B | Score C | Wtd A | Wtd B | Wtd C |
|---|---|---|---|---|---|---|---|
| TOTAL | -- | -- | -- |
Recommended vendor price updated in Infrastructure capex automatically.
Section 11
Master Checklist
71 checkpoints across 10 modules.
Section 12
DPR & Collateral Register
DPR Document Checklist
Section 13
Results & Executive Summary
Executive Summary
Reference: -- | Date: --
Complete all sections to generate the executive summary.
PEPC - Paarminder Singh Electronic Process ConsultancyCONFIDENTIAL | FOR INTERNAL USE ONLY
Complete Results Summary
Section 14
Export
Export Options
📊 Generate PowerPoint Presentation
Input Summary