Value Analysis And Value Engineering 6926e

VALUE

Value (P)

= Desired performance Overall Costs (C)

Value can be increased by either improving the Performance or reducing the cost.

VALUE METHODOLOGY Value Methodology (also called Value

Engineering, Value Analysis or Value Management) is a powerful problemsolving tool that can reduce costs while maintaining or improving performance and quality requirements.

It is a function-oriented, systematic

team approach to providing value in a product or service.

Continued…. The value methodology helps organizations

compete more effectively in local, national and international markets by: - Decreasing costs - Increasing profits - Improving quality - Expanding market share - Saving time - Solving problems  Using resources more effectively

Value Analysis VA is an step by step approach to identify the functions of a product, process, system or service; to establish a monetary value for that function and then provide the desired function at an overall minimum cost without affecting any of the existing parameters like Quality, Maintainability, Productivity, Safety and other Performance characteristics.

Value Engineering Value Engineering is where the value of all

the components used in the construction of a product from design to final delivery stage are completely analyzed and pursued.

Origin  Value Engineering began at General Electric Co. during World War II. Because

of the war, there were shortages of skilled labor, raw materials, and component parts. Lawrence Miles and Harry Erlicher at G.E. looked for acceptable substitutes. They noticed that these substitutions often reduced costs, improved the product, or both. What started out as an accident of necessity was turned into a systematic process. They called their technique as “Value Analysis”.

 In the year 1954, US Navy Bureau of ships adopted same technique in their

effort at ‘cost avoidance’ during the design stage and saved millions of dollars. They named it as “Value Engineering”. VE follows thought process that is based exclusively on “function”, i.e. what something ‘does’ not what it is.

DIFFERNCE BETWEEN VALUE ANALYSIS AND VALUE ENGINEERING VALUE ANALYSIS  Indicates application on the product that is into manufacturing.  All factors come together including workers, subcontractors, engineers to make a team with total experience and knowledge

VALUE ENGINEERING  Indicates application on the product at its design stage.  It is always done by a specific product design (engineers) team.

DIFFERNCE BETWEEN VALUE ANALYSIS AND VALUE ENGINEERING VALUE ANALYSIS It may change the present stage of the product or operation It is worked out mostly with help of knowledge and experience

VALUE ENGINEERING the changes are executed at the initial stages only. It requires specific technical knowledge.

WHAT IS THE MEANING OF OVERALL COSTS? Overall costs means different to different people. For a producer overall cost is the summation of all

the elements of the cost required to produce a product or service such as labour, material, overhead, etc. For a consumer overall cost is the monetary sum (price) for which the products or services are purchased in the market.

The value of a function can be increased by four methods 1. 2. 3. 4.

Decrease the cost while ensuring the same level of performance. Enhance the performance at the same cost. Decrease the cost and increase the performance Increase both performance and cost ensuring that performance increases more than the increment in the cost.

VALUE ANALYSIS TESTS     

Does its use contribute value? Is its cost proportional to its usefulness? Does it need all its features? Is there anything better for the intended use? Can a usable part be made by a lower cost method?

VALUE ANALYSIS TESTS Can a standard product be found which will be

usable? Is it made on proper tooling, considering quantities used? Do materials, reasonable labour, overhead, and profit total its cost? Will another dependable supplier provide it for less? Is anyone buying it for less?

FUNCTION OF VA/VE

FUNCTION HERE MEANS NEED

THE VARIOUS TYPES OF FUNCTION ARE AS FOLLOWS: 

Use function and Aesthetic function



Primary function and secondary function



Higher order and secondary function

USE FUNCTION AND AESTHETIC FUNCTION



Use function-Performs some action, expresses in active tone



Aesthetic function-Pleases customer, expressed in ive or non-measurable tone

Primary function and secondary function 

Primary function - Basic purpose for which a product exists



Secondary function - Arises out of specific design chosen to fulfill the primary function

Higher order and secondary function 

Higher order function - Reason of satisfying the basic function



Lower order function - Means of achieving the basic function

EXAMPLE FUNCTION OF A TORCH WHY? GIVE LIGHT

HOW ? FACILITATE VIEWING

HOW ?

HOW ? SUPPLY CURRENT

INSERT BATTERY

LIGHT THE BULB

Job Plan with Specific Phases Orientation Information Function Creation Evaluation Recommendation Implementation Audit/Follow up

Orientation To creat awareness and learn the methodology of tools Training sessions for all supervisory and managerial staff on VA & VE Exposure to techniques like ABC, Pareto etc. for selection of project Formation of team of experts from various functions

Information To collect all the information pertaining to the project (product) Work can be divided among team

Function To develop FAST diagram Start from basic function and probe further with WHY? And HOW? List down all the functions for all the parts

Creation To develop alternate means to achieve these functions Brainstorming sessions to generate ideas

5. Evaluation phase: The objective of this is to select for further analysis of the most promising of the ideas generated during the creative phase and to subject the ideas to a preliminary screening to identify those which satisfy the following criteria. Will it work? Is it less costlier than the present design?  Is it feasible to implement?

There are four techniques associated with this phase:  Refine and combine ideas: The ideas must be practicable an to make them so we may have to refine an idea or combine two or more than two ideas  Estabilish cost on all ideas: calculating potential costs of implementing the ideas.  Develop function alternatives: Mould the individual functional solutions into total solutions.  Evaluate by comparison: Once the rough total solutions and their related estimates of costs have been established, they are compared to determine which one will provide the greatest value advantage.

6. Recommendation Phase: To submit the details about the proposed changes with financial implications. Report includes proposed changes, reasons of changing, new investments and annual savings.

7. Implementation: To execute the proposed/ accepted changes list down all the activities and fix up the time frame for each. Make the entire team responsible for all the activities.

8. Audit / Follow up: To compare the actual results with that of expected. It can be done only after complete execution of the project. This is the responsibility of top management alone.

THE RED POINTER AND RED INK

 On

an appliance knob, a strip of bright metal containing a red pointer was mounted.

 Function:

knob conceals the screw and provides the appearance which the customer wished.

 The

value audit of the product showed that $20000 was spent each year on the production of 1 million pieces.

 Developing A

alternatives to reduce costs.

polished stainless steel part was one alternative which would accomplish the function and be liked by the customer as well.



The industrial stylist asked, “Why does the red pointer increase the cost so much?”



The answer was that it caused the small part to become a “name plate”, which imposed certain costs and restrictions on its manufacture and procurement.



Some of the other alternatives, such as the polished stainless steel, were merely small stampings not using name plate technology and not limited to the sources of supply who provide name plates.



Instructions by stylist: to take out the red pointer and use polished stainless steel. the red arrow was not good, that it caused the product to look more like a toy and less the mature and he never had liked the red color

 



The change was made, both improving the customer appearance value of the product and eliminating 815,000 of unnecessary cost .



Although the answer , once developed, and the thinking process seen simple, $15,000 cash each year ($1250 each month) for the design life of three to four years shows the benefits of an optimum problem solving system for simple as well as involved matters.



Value analysis is a problem-solving system implemented by the use of a specific set of techniques, a body of knowledge, and a group of learned skills.



An organized creative approach to efficiently identify unnecessary costs



Leads to orderly utilization of better approaches, alternative materials, newer processes, and abilities of specialized suppliers.



It focuses engineering, manufacturing and purchasing attention on one objective-equivalent performance for lower cost.



Step by step procedures for accomplishing its objectives efficiently with assurance.