Product Design and Value Engineering By Dr. M. A. Bulsara, Dr. H. R. Thakkar

(4) Involvement/Detachment
(5) Use of metaphor
3-7. Product development organization
3-7-1. Structure of typical engineering organization
(1) Design, research and development department (What to
produce?)
(2) Planning department (How to produce?)
(3) Manufacturing department (Produce)
(4) Inspection and quality control department (Quality
Control)
(5) Purchase department (Procurement of raw material)
(6) Tool design department (Jig, fixture design)
(7) Servicing department (After sales services)
(8) Administration department (Managing human resource)
(9) Sales and Marketing Department (How much to produce?)
3-7-2. Structure of Product development organizations
(1) Project oriented structure
(2) Function oriented structure
(3) Hybrid (matrix) structure organization
(4) Selecting an organization structure
(5) Requirement of cross-functional expertise
(6) Requirement of cutting-edge (advanced) functional
expertise
(7) Utilization of experts for complete duration of project
(8) Project completion schedule
(9) Case study
(10) AMF development process
(11) The AMF organization structure
3-8. Overview
(1) Brainstorming
(2) Brain writing
(3) The idea game
(4) Morphological analysis
(5) Forced relationship
(6) A systems approach
(7) Varied perspective
(8) Archival analysis
(9) Inventive templates
(10) Synectics
Exercise 3

Chapter 4 PRODUCT DEVELOPMENT PLAN

4-1. Introduction
4-2. Product Life Cycle
4-3. New Product Development – NPD
4-3-1. New Product Development Funnel
4-3-2. Empathic design
4-4. Appropriate time for introducing new product
4-5. Planning the product development process
4-5-1. Proposing organization goal
4-5-2. Identify potential products
(1) Employees of the organization
(2) Senior officers of the organization
(3) Sales and marketing staff
(4) Magazines
(5) Competitors’ product brochure
(6) Customer reviews
(7) Research and development organization
(8) Thrust areas identified by government
(9) Educational institutes
(10) Hiring specialist
(11) Crisis of natural resources
(12) Changing life style
4-5-3. Selection and Evaluation of project (product)
4-5-3-1. Selection of project (product)
(1) Technology consideration
(2) Technological development cycle
(3) Infrastructure consideration
(4) Market segment
(5) Demand
4-5-3-2. Evaluation of project (product)
(1) Project rating (4) Strategic cluster
(2) Ranking (5) Interactive decision
(3) Simulated outcome
4-5-4. Resource allocation

4-5-5. Deciding product dev. goals
4-5-6. Review of product planning
4-6. Overview
Exercise 4

Chapter 5 IDENTIFYING CUSTOMER NEEDS

5-1. Introduction
(1) Product name
(2) Basic Function
(3) Outstanding features
(4) Business goal
(5) Financial constraint
(6) Market segment
(7) Customers
(8) Major constraints
(9) Expected selling price
(10) Time frame to introduce the product
(11) Use of existing resources and technology
5-2. Gather information from customer
(1) Selection of customer
(2) Methods for gathering customer needs
(3) Eliciting customer needs
(4) Documentation of customer needs
(1) Audio recording
(2) Video Recording
(3) Text writing
5-3. Interpretation of raw data
5-4. Arrange customer needs based on hierarchy
5-5. Establish significance of customers needs
5-6. Trade–off in deciding importance of the needs
5-7. Quality Function Deployment
(1) QFD and house of quality (HoQ)
(2) Steps in preparing of House of Quality (QFD)
Case study 1
QFD analysis for a Clothes Drying Stand
Case study description
(1) Enlist the customer needs
(i) Aesthetic and Ergonomic requirements
(ii) Performance requirements
(2) List the “Parameters affecting customer needs” (How
these customer needs can be achieved?)
(i) Material selection
(ii) Manufacturing processes
(3) Develop a relationship matrix between what and how?:
(4) Develop an interrelationship matrix (Relation between
hows?)
(5) Make competitive assessment of design attributes. (Rating
of factors affecting design)
(6) These priorities indicate the direction / action to improve
the products
Case study 2
QFD analysis for a ceiling fan
5-8. Advantages of QFD
5-9. Review and Revision
5-10. Overview
(1) Establishing the mission statement
(2) Gather information from customers
(3) Interpretation of raw data
(4) Trade-off in deciding importance of needs
(5) Review and revisions
Exercise 5

Chapter 6 DECIDING PRODUCT SPECIFICATIONS

6-1. Introduction
Product Specification
6-2. Establishing target specifications
(1) Prepare a list of measurable
(2) Collect competitors’ data (Benchmarking)
(3) Set the range of target values
6-3. Setting the final specifications
(1) Develop different concepts of design
(2) Calculate cost of product for alternative design
(3) Strike out final specification based on trade-off
6-4. Review and Revisions
6-5. Overview
Exercise 6

Chapter 7 VALUE ENGINEERING: AN OVERVIEW

7-1. Introduction
7-2. Cost reduction techniques
(1) Operation research
(2) Time and motion study
(3) Use of mass production techniques
(4) Standardization
(5) Make-buy decision
(6) Simplification
7-3. Definition of Value Engineering
7-4. What is value?
(1) Use value (3) Exchange value
(2) Esteem value (4) Cost value
7-5. Value Engineering Programme (VEP)
(1) Selecting a product or service for study
(2) Obtaining and recording information
(3) Analyzing the information and evaluating the product
(4) Working out alternatives
(5) Selecting the least cost alternative
(6) Recommendation
(7) Implementation
7-6. Advantages of value engineering
7-7. Reasons for unnecessary cost
7-8. Objectives / Reasons for value analysis
7-9. Concept of value engineering
(1) What is the product? (Selection of product)
(2) What must it do? (Evaluation of function)
(3) What does it cost? (Evaluation of cost)
(4) What is it’s worth? (Evaluation of worth)
(5) What else would work? (Working out alternatives)
(6) What does it cost? (Evaluation of cost of alternatives)
7-10. Areas of application value engineering
7-11. Overview
Exercise 7

Chapter 8 VALUE ENGINEERING JOB PLAN

8-1. Introduction to value engineering job plan
8-2. Orientation phase
8-3. Information phase
8-4. Function phase
8-4-1. Evaluation of function
(1) Express function in two words
(2) Quantify noun (4) Categorize function
(3) Choose broad verbs (5) Emphasize on aesthetics
8-5. Creation Phase
(1) Brain storming
(2) Blast, Create and Refine
(3) Check list
(4) Morphological analysis
(5) Delphi method
(6) Attribute listing
(7) FAST Diagram
8-6. Evaluation phase
(1) Number of components in assembly
(2) Number of features on component
(3) Design features to be machined in single set-up
(4) Use of symmetry
(5) Ease of assembly
(6) Ease of manufacture
(7) Use of standardized parts
(8) Service and maintenance of equipment
(9) Availability of vendor and their reliability
8-7. Investigation Phase (Development phase)
8-8. Recommendation (Presentation) and Implementation Phase
8-9. Overview
Exercise 8

Chapter 9 VALUE ENGINEERING: PROJECT SELECTION
AND VALUE STANDARD

9-1. Value Engineering (VE) Project selection
9-2. Methods used for VE project selection
(1) Felt need

(2) Review by steering committee
(3) Suggestion schemes
(4) Seminars / brain storming
(5) Relative ranking
(6) Why-Why analysis
(7) Assessment of Value index
9-3. When to apply value engineering methodology
(1) Application of VE during Product Dev. Process
(2) Application of Value Engineering during Product Life Cycle
9-4. Value standard
(1) Information Phase
(2) Function Analysis Phase
(3) Creation Phase
(4) Evaluation Phase
(5) Development Phase
(6) Presentation Phase
9-5. Overview
Exercise 9

Chapter 10 FAST DIAGRAM AND LIFE CYCLE COST

10-1. Introduction
10-2. Uses of FAST diagram
10-3. Types of FAST diagram
10-4. Technically oriented FAST diagram
10-4-1. Layout of FAST diagram
10-5. Case study (technically oriented FAST diagram)
10-5-1. Case Study 1: O.H.P.
10-5-2. Case Study 2: Lathe Machine
10-5-3. Case study 3: Air conditioner
10-6. Tips for preparing FAST dia.
10-7. Customer (Task) oriented FAST diagram
10-8. Life Cycle Cost (LCC)
(1) Development cost
(2) Direct Material Cost
(3) Direct Labour Cost
(4) General expenses
(5) Factory expenses
(6) Sales expenses
(7) Maintenance and repair cost during service life
10-8-1. Time Value of Money
10-8-2. Evaluation of life cycle cost
10-9. Overview
Exercise 10

Chapter 11 INITIATING VALUE ENGINEERING PROGRAM

11-1. VE training Prg.: Introduction
11-2. Implementation of VE training program
(1) Training coordinator
(2) Training plan
(3) Training capability
11-3. Categories of training
(1) Limited training (Level I)
(2) Intensive training (Level II)
(3) On the job training
(4) Training by rotational job assignment
(5) Contractual training
(6) Informal training
11-4. Workshop / Seminar
(1) Priority of Attendance
(2) Duration and Session Schedule
(3) Participants
(4) Team Organization and Responsibility
(5) Workshop Projects
(6) Workshop Leadership
(7) Vendors
(8) Curriculum
11-5. Career development for VE specialities
11-6. Value Engineering Team
11-6-1. Value Engineering Team Leader
11-6-2. Value Engineering Project manager
11-6-3. Full-time VE Team Members
11-6-4. Part-time VE Team Members
11-7. VE Coordinator / Facilitator

11-8. VE Level of Effort
11-9. Definitions
(1) Value Engineering (VE)
(2) Value Analysis (VA)
(3) Project Cost
(4) Worth
(5) Value
(6) Function
(7) Basic Function
(8) Secondary function
(9) Higher order function
(10) Required secondary function
(11) Assumed functions
(12) Supporting functions
(13) Function Analysis
(14) FAST diagram
(15) VE Job Plan
(16) VE Project
(17) Life cycle cost
11-10. Overview
Exercise 11

Chapter 12 DESIGN FOR MANUFACTURE

12-1. Introduction
12-2. Capability and capacity of machine
12-3. Advantages of design for manufacture
12-4. Common Manufacturing processes
12-5. Design guidelines for sheet metal work
(1) Width to thickness ratio for punching
(2) Accuracy of punched hole
(3) Bending of sheet
(4) Height to thickness ratio
(5) Placement of hole
(6) Relieving the Bend
(7) Bending in perpendicular directions
(8) Reduce wastage
(9) Limitation of roll bending
(10) Grain orientation and bending
12-6. Design guidelines for machined part
(1) Design for reduced setups
(2) Design shape according to standard cutters
(3) Avoid deep hole drilling
(4) Drill can produce only straight holes
(5) Drilling on inclined surface
(6) Depth of blind hole for post drilling operation
(7) Placement of hole
(8) Design section to resist cutting and/or clamping force
(9) Chamfers are preferred over fillet
(10) Clamping of work piece
(11) Provide free space for drill jig
(12) Avoid machining if possible
(13) Avoid machining in narrow space
(14) Provide relief for tool
12-7. Design guidelines for cast components
(1) Prevent hot spot at sharp corners
(2) Provide draft in pattern
(3) Maintain uniform thickness of cross-section
(4) Design junction to avoid hot spot
(5) Material distribution
(6) Web design in pulley
(7) Relative size of section
(8) Avoid sharp corners
(9) Cored holes
(10) Spacing of ribs
(11) Avoid solid hub
(12) Design for straight parting line
(13) Avoid abrupt changes in cross-section
12-8. Design guidelines for welded joints
12-9. Design guidelines for injection moulded components
(1) Optimize the section thickness
(2) Provide suitable draft

(3) Avoid sharp corners
(4) Avoid abrupt changes in cross-section
(5) Design bosses carefully
12-10. Design guidelines for Plastic part
12-10-1.Types of plastics and properties
12-10-2.Design factors to improve mouldability
12-10-3.Failure of plastic parts
(1) Mechanical failure
(2) Thermal failures
(3) Environmental failures
12-10-4.Design consideration for Plastic parts
(1) Shrinkage
(2) Uniform wall thickness
(3) Reducing sink marks
(4) Radius all corners
(5) Holes
(6) Reinforcement features
(7) Gate location
(8) Ejector pin marks
12-10-5.Engineering applications of plastic parts
12-11. Design guidelines for Rubber part
12-11-1.Properties of Natural Rubber
12-11-2.Types and properties of rubber
12-11-3.Manufacturing of Rubber Products
12-11-4.Design consideration of Rubber Parts
(1) Wall thickness
(2) Holes
(3) Undercuts
(4) Screwed threads
(5) Inserts
(6) Draft
(7) Corners (Radii and fillets)
(8) Flash
(9) Parting line
(10) Distortion in rubber
(11) Wobble and eccentricity
12-12. Design guidelines for Ceramics and Glass parts
12-12-1.Properties of ceramics
(1) Chemical properties
(2) Mechanical properties
(3) Physical properties ceramics and glass
(4) Thermal properties
(5) Electrical properties
(6) Magnetic properties
12-12-2.Manufacturing of Ceramic components
(1) Moulding
(2) Densification
(3) Applications of ceramics
12-12-3.Design aspects of Ceramics
(1) Tolerance dimensions as loosely as possible
(2) Limit component thickness
(3) Avoid features which cause stress concentrations, such
as sharp edges and corners, sudden changes in cross-sectional
area and small contact points
(4) Keep the component form as simple as possible
(5) Keep wall thickness as uniform as possible
(6) Avoid unnecessary diamond grinding
(7) Use modular design
12-13. Overview
Exercise

Annexure I : TYPICAL TRAINING PROGRAM FOR A 40-HOUR VALUE ENGINEERING TRAINING WORKSHOP COURSE

Annexure II : CASE STUDY: MARKET PULL PRODUCT
DEVELOPMENT OF BICYCLE

Annexure III : PAPER SOLUTIONS OF PREVIOUS GTU
EXAMINATIONS

Index