International Journal of Electrical, Electronics and Computer Systems (IJEECS)
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Implementation of Value Engineering in Development of Universal Mobile Holder
1Rohan Kothurkar, 2R. K. Agrawal
1B.E. in Mechanical Engineering, Pune University,
2R.K.Agrawal MTech Machine Design, HOD Mech, Yadaorao Tasgaonkar College of Engineering and Management, Abstract: In this paper we have discussed the concept of
Value Engineering, its job plan and the effective implementation of it to Universal Mobile Holder. The best feasible solution from the available alternatives is chosen through the feasibility ranking table. As Value = Function/
Cost, aim of our work is to improve products value by increasing functions and aesthetic by keeping cost constant or by slightly increasing cost. We have used Solid Works software for 3D modeling and evaluation.
Keywords: Value Analysis, Weight reduction, Function improvement, Material Saving.
I. INTRODUCTION:
The need of value analysis is when the product scale is in trouble, Things are not going well, and product is in decline state in product life cycle. Then we should start asking questions like Are we responsible to customers need? Dose we have product features and functions customer pays for and doesn’t need? Dose customer need functions and features we don’t provide? Have we investigated range of alternative ways to satisfy market requirement? From that range, have we selected the option that is most cost effective? Do we know which of our product feature is value adding? Is there room for improvement, is it better to find before computation dose?
Value analysis is fundamentally different from traditional approaches to design, Cost reduction, production engineering and industrial design. The key difference is that value analysis offers a method for identifying and selection lowest cost approach, from many alternative methods, to satisfy proper function needs.
Value analysis is based on a methodology developed by Electrical Engineer Lawrence Miles, who worked for the General Electric Company in the USA during the Second World War. Because of the war, there were shortages of materials and certain finished products.
However, manufacturing industry was running at maximum capacity, and ideas where needed to further expand production. Miles was responsible for purchasing raw materials for the General Electric Company. He came up with the idea that if he was unable to obtain one particular material, then it was
necessary to obtain a replacement material which performed the same function.
II. VALUE ANALYSIS PRINCIPLES
Value analysis principles consist of key questions, techniques, and procedural tasks used in pursuing the objective of the value analysis job plan. The objective is to achieve design excellence by completing each of the following phases:
1. Information Phase
The value analysis team has reviewed the project design, objectives, and the preliminary cost information. They understand the limitations on the project as well as the expected benefits.
2. Function Analysis Phase
The team has defined the project functions using a two- word active verb/measurable noun context. The team has reviewed and analyzed these functions to determine which need improvement, elimination, or creation to meet the project's goals.
3. Creative Phase
The team has employed professional creative techniques to identify other ways to perform the project's function(s).
4. Evaluation Phase
The team has followed a structured evaluation process to select those ideas that offer the potential for value improvement while delivering the project's function(s) and considering performance requirements and resource limits.
5. Development Phase
The team has developed the selected ideas into alternatives (or proposals) with a sufficient level of documentation to allow decision- makers to determine if the alternative should be implemented.
6. Presentation Phase
The team leader has developed a workshop report and/or presentation that documents and conveys the adequacy
of the alternative(s) developed by the value team to the decision-making body of the proponent agency
Finally under the Implementation Phase, Management Team has selected the value alternative to be implemented and directs the proponent agency's project team to proceed with the next steps
III. VALUE ANALYSIS AS MAJOR PART OF PRODUCT DEVELOPMENT
At the present moment, global competition between companies is leading to a constant battle for an adequate market share and this is mostly not only achieved by reducing prices but rather more effectively by constantly introducing new innovations at all levels and across all functions.
While developing existing product using value analysis following points should be taken into consideration:
1) Product should be superior to previous.
2) Product should be adapted to the buyers' financial capabilities.
3) Either there is reduction in cost or increase in functions.
4) Product placed in the market at the right time.
There are many reasons for a structured approach of the value analysis as a means of a logical cost reduction.
These reasons can be divided according to their source – reasons found inside a company (insufficient information in terms of design) or reasons initiated by the product’s or service’s market (pricing, environmental protection, new technologies, materials etc
EXISTING PRODUCT:
Fig 1 - Flexible Long Arm Mobile Phone Holder Stand Product used for hands free comfort on mobile phone while watching a movie or doing a Face time video chat.
The long flexible stand can be conveniently shaped to provide with a perfect viewing angle as per the needs.
The clamp is strong and rigid enough to be fixed to your study table or even your bed. So now while you are going to sleep or are studying, one can just have your phone at a convenient position without having the difficulty of holding it. The holder can rotate a full 360 degrees. The device can hold all phones up to 11in size so that makes it perfect for smart phones.
Problems with existing product:
Clamp is made up of metal which is heavy.
Clamping circular objects is difficult and clamp becomes unsteady.
Clamp design is poor and aesthetically not pleasing.
It has very few functions and there is huge scope of improvement.
AIM OF MY WORK:
Value = Function/ Cost
Here we have to increase value of product this can be done by:
Function increase, cost decrease
No change in function reduced cost
No change in cost increased functions
Reduce function and reduce cost
Aim of my work is to improve products value by increasing functions and aesthetic by keeping cost constant or by slightly increasing cost.
PRESENT INVESTIGATION:
FUNCTIONAL ANALYSIS PHASE:
Our focus is towards developing a special product universal mobile holder. Firstly, we identified the functions the product should have and in the next step we divided them according to the type and whether the function was new or existing.
Sr.
No
Verb Noun Type (Basic/
Secondary)
1 Clamp Table B
2 Clamp Mobile B
3 Prevent Movement S
4 Have Strength S
5 Enable Rotation S
(Table 1) Functional Matrix of assembly.
Sr.
No
Component Verb Noun Type
(Basic/
Secondary) 1 Table Clamp Clamp Table B
2 Mobile clamp Clamp Mobile B 3 Ball and
socket
Allow Rotation S 4 Goose neck Allow Positioning S 5 Torsion
Spring
Provide Stiffness S
6 Rubber Provide Grip S (Table 2) Functional matrix of individual component CREATIVITY PHASE
Theme of this phase is, “Which are the other alternatives for the same functions” of the handle assembly. Many ideas are generated and discussed in the brain storming session.
Brain storming.
In this session every member of the committee is encouraged to generate ideas and weirdest ideas are also encouraged. Many ideas are generated and top six ideas are listed below:
1) Use Plastic Table clamp instead of metal 2) Modify design so that it can clamp to round bar.
3) Make it multifunctional i.e. for Table as well as for round bar, bicycle and car steering.
4) Use another material for goose neck as it is heavy.
5) Use C Clamp For Clamping.
6) Use aluminum for clamps.
7) Use Plastic Ball in ball and socket joint instead of metal.
After that comparison between functional matrix of new and existing product is done. So that we can review new and existing functions.
Sr.
No.
Name of function Existing Product
New product
1 Enable Clamping Mobile Y Y
2 Enable clamping table Y Y
3 Enable rotation Y Y
4 Enable Clamping round bar N Y
5 Enable clamping bicycle handle
N Y
6 Reduce vibration Y Y
7 Provide grip Y Y
8 Enable clamping starring wheel
N Y
9 Enable positioning Y Y
(Table 3) Functional matrix of new and existing product (Y – Yes N - No)
EVALUATION PHASE
The objective of the evaluation phase of the value analysis job plan is to analyze the results of the creativity phase and, through review of the various alternatives, select the best ideas for further expansion.
PRELIMINARY SCREENING TECHNIQUES Several techniques are available to evaluate alternate ideas. Examples are as follows:
1 ) Comparison Technique.
2 ) Advantages Versus Disadvantages Technique.
3 ) Ranking Technique.
4 ) Probabilities Technique.
We are using ranking technique here:
The ranking technique allows the evaluators to assign a numerical rating to the alternates. Start this process by judging an excellent idea to be worth 5 points; a good idea, 4 points; a fair idea, 3 points; a poor idea, 2 points;
a very poor idea, 1 point. Group all 5-point ideas and evaluate further. Use the same method on all 4-point ideas, and, if necessary, on the 3-point ideas.
5 points- excellent ; 4 points- good ; 3 points - fair ; 2 points - poor ; 1 point - very poor
Parameter P.O.I B.O.I Weight Reduction
Appearance Usability Total
Existing 5 1 3 2 1 12
Idea 1 5 3 4 3 4 19
Idea 2 5 5 2 2 4 18
Idea 3 5 5 4 4 5 23
Idea 4 2 4 3 3 3 15
Idea 5 4 1 2 1 1 9
Idea 6 4 4 4 2 3 13
Idea 7 3 3 4 3 3 16
(Table 4) Ranking Technique P.O.I – Probability of implementation.
B.O.I – Benefits of implementation.
DEVELOPMENT PHASE:
This phase is an objective appraisal of the alternatives that provide the best value for reliably performing the required functions. During this phase the most promising alternatives selected during the evaluation
phase will be further developed into detailed alternative designs. The intent is to obtain and present convincing data regarding design changes and costs for presentation to management.
The best alternatives are completely developed, with the assistance of experts and specialists, as required.
Recommended design changes, materials, procedures, new forms, changes to standards and policy, all costs,
and implementation requirements have to be documented. Develop each alternative until enough data has been accumulated to prove it is the best choice. If there are other similar alternatives that are also options to the existing situation, develop the next best idea enough to prove its potential. If management rejects the teams preferred alternative perhaps the second alternative may serve as a fallback recommendation that is still an improvement over the existing design.
In my Case Existing product has 12 rank. And idea 1, idea 2, idea 3 and idea 7 have 19, 18, 23 and 16 ranks respectively. Those ideas were Use Plastic Table clamp instead of metal which results in reduction of weight from 128gm to 72 gm. Manufacturing Cost of metal clamp is around Rs. 60 while that of ASB Plastic is Rs45.Make it multifunctional i.e. for Table as well as for round bar, bicycle and car steering and Use Plastic Ball in ball and socket joint instead of metal which also cause reduction in weight from 15gm. to 2gm. So I have developed Product taking these ideas in consideration.
NEW PRODUCT
EXPLODED VIEW
Fig : 2 -Developed product (3D Model using Solid Works 2013).
We can also remove gooseneck and assemble it so that it can be use fir bike or car. Assemble is shown below:
ANOTHER COMBINATION
EXPLODED VIEW
Fig 3 - Developed product (3D Model using Solid Works 2013).
IV. CONCLUSION:
We can conclude that an objectively determined value of a product plays a vital role if we want to make a product truly interesting for a customer or the user and if we want to fulfill his/her expectations. In this I have increased functions of product thereby increasing value.
In addition, changing material of clamp from steel to ASB plastic results in weight reduction from 128gm to72gm.Also cost of metal clamp is Rs 60/- while that of plastic is Rs 45/-Changing material of ball in ball and socket joint from steel to ASB plastic also cause reduction in weight from 15 gm to 2 gm.
FUTURE SCOPE:
We can find appropriate material for gooseneck which will reduce weight as well as cost. We can also optimize shape so that less material is used resulting in less cost.
REFERENCES
BOOKS:
[1] Value Analysis Handbook June 2009 Australian Government.
[2] Value Analysis Tear-down: A New Process for Product Development and Innovation, Yoshihiko Sato, J. Jerry Kaufman.
[3] Product Design and Value Engineering, Dr. M.
A. Bulsara and Dr. H. R. Thakkar
[4] Techniques of Value Analysis and Engineering by L.D. Miles
RESEARCH PAPERS:
[1] Value Analysis as an Integral Part of New Product Development Marjan Lebera, Majda Bastiča, Marko Mavriča, Andrea Ivaniševićb, 24th DAAAM International Symposium on Intelligent Manufacturing and Automation, 2013 [2] Application of value analysis in processes of cog-
wheels production , M.T. Roszak*, D.
Szewieczek, Journal of Achievements in Materialsand Manufacturing Engineering, Volume 20 Jan 2007
[3] Achieving Success through Value Engineering: A Case Study Amit Sharma, R.M. Belokar
Proceedings of the World Congress on Engineering and Computer Science 2012 Vol II WCECS 2012, October 24-26, 2012, San Francisco, USA
[4] Implementation of Value Engineering: Case Study By Amit Sharma, Dr R M Belorkar International journal of marketing Volume 1 No 3 March 2012 ISSN 22773622
[5] Value Analysis for Mumbai Local Train Bhaskar B. Gardas, Naresh R. Shimpi, Sunil B. Mahajan International Journal of Scientific and Research Publications, Volume 3, Issue 6, June 2013 1 ISSN 2250-3153
[6] Technological value analyses of mechanisms used in amusement parks liviu marian ungureanu, cristian gabriel alionte , danuta aurica grad,ioan dan filipoiu, U.P.B. Sci. Bull., Series D, Vol. 76, Iss. 3, 2014, ISSN 1454-2358
[7] Application of value engineering for cost reduction – a case study of universal testing machine Chougule Mahadeo Annappa and Kallurkar Shrikant Panditrao International Journal of Advances in Engineering &
Technology, July 2012.IJAET Achieving Success through
[8] Value Engineering: A Case Study, Amit Sharma, R.M. Belokar Proceedings of the World Congress on Engineering and Computer Science 2012 Vol II WCECS 2012, October 24-26, 2012, San Francisco, USA
