Included as Case Study in Industrial Engineering ONLINE Course
Industrial Engineering Case Studies Collection
Techniques of Value Analysis and Engineering by Lawrence D. Miles, First Edition, 1961.
Cost reduction through value analysis and engineering.
Value Engineering - Introduction
_____________
Techniques of Value Analysis and Engineering by Lawrence D. Miles, First Edition, 1961.
Cost reduction through value analysis and engineering.
Value Engineering - Introduction
_____________
_____________
Alternative ways of fulfilling the function, alternative materials, alternative processes, alternative suppliers
Examples
Electrical Control - Pp.1-2
Component wire clip made of phosphor bronze costing $7000 a year for the annual consumption quantity.
Function: Held the cover. cover opened for servicing expected to be done six times in the life time of the device.
What else will do the job?
Clip made of spring brass
Cost: $3000
The cover of the instrument cost 4 cents - total expenditure of $40,000 for the annual consumption quantity.
Function: to keep extraneous material out.
The control was mounted inside another closure.
What else will do the job?
Plain piece of plastic.
Cost: 1.5 cents. Total expenditure $15,000.
Case Study - Control - P.10,11
Standard catalogue item found for 25 cents
Sub-assembly supporting an emergency control lever designed cost $20.33
VA led to new cost of $8.12
When new order came with some modifications to design, the old analysis helped it also.
Case Study - Radiation Control P.12-13
Cost: $50,000
What else will do the job?
Sand will 14 feet thick and 14 feet high. Cost $5000
It pays to enquire what else will do the function required?
Alternative ways of fulfilling the function, alternative materials, alternative processes, alternative suppliers
Examples
Electrical Control - Pp.1-2
Example: VA of electrical control instrument
Component wire clip made of phosphor bronze costing $7000 a year for the annual consumption quantity.
Function: Held the cover. cover opened for servicing expected to be done six times in the life time of the device.
What else will do the job?
Clip made of spring brass
Cost: $3000
The cover of the instrument cost 4 cents - total expenditure of $40,000 for the annual consumption quantity.
Function: to keep extraneous material out.
The control was mounted inside another closure.
What else will do the job?
Plain piece of plastic.
Cost: 1.5 cents. Total expenditure $15,000.
Case Study - Control - P.10,11
Case Study: Control consisting of electrical and mechanical components
Component: Metal knob - designed cost $2.25Standard catalogue item found for 25 cents
Sub-assembly supporting an emergency control lever designed cost $20.33
VA led to new cost of $8.12
When new order came with some modifications to design, the old analysis helped it also.
Case Study - Radiation Control P.12-13
Case Study: Radiation Shield for X-Ray testing room for large forgings and castings.
Designed suggestion: Build a concrete wall 7 feet thick and 14 feet high.Cost: $50,000
What else will do the job?
Sand will 14 feet thick and 14 feet high. Cost $5000
It pays to enquire what else will do the function required?
CS - The Pivot Pin 32-35
Case Study: Pivot pin
Cost $3.65
Quantity consumed : 50 million
Supplier said he could not reduce price due to features and tolerances.
Every feature and tolerance of the pin were questioned.
23 questions and answers were given by L.D. Miles in the book.
The pin is made from stainless materials that costs 45 cents per unit. The manufacturing cost is $3.25 per piece, mainly because of + or - 0.001 in length tolerance, 0.00025 in diameter tolerance, the camfer as well as radius at the end of the pin, machining hardened 440 stainless steel.
Based on the detailed investigation, the supplier was asked quote for 0.0005 inch diameter tolerance, sample based inspection, and a reduced size material for blank.
5 alternatives were developed and suppliers were asked to quote.
Method two, which is method 1 + method 2 was quoted $1.90 per thousand and accepted.
In method two, 0.0005 inch diameter tolerance, sample based inspection, and a reduced size material for blank were the changes.
Value analysis involves detailed evaluation of each feature of the part design and a reengineering or redesign based on engineering ideas for improvement or cost reduction.
Related Posts
Updated on 8 June 2021
Pub 5 May 2021
No comments:
Post a Comment