Value engineering can be defined as the process of relating the functions, the quality, and the costs to determine optimum solutions for the project

1. APPROACH TO
VALUE ENGINEERING
USING PRO/ENGINEER
“Engineering is the conceptualization, design, construction, and
administration of projects and products. Whatever the field or application, an
engineer solves problems with imagination, creativity and synthesis of various
sources of knowledge”.
W H I T E P A P E R S

2. O view
ver
VALUE ENGINEERING
Value engineering is a tool wherein its application on projects and products helps achieve its
whole-life value. Essentially, the project or product is viewed from its purpose and function
right through to its conception, actualization / manufacture, usage and simultaneously in a
reverse order from its usage back to its purposes and functions.
Value engineering has its origin in the manufacturing industry; its methodology has been
developed for use in design projects. The realization of whole-life value for a design project
involves finding optimum combinations of initial project costs, maintenance costs, and costs
associated with the time for completion of the project.
Value engineering can be defined as the process of relating the functions, the quality, and the
costs to determine optimum solutions for the project.
The procedures of value engineering lead to a solution that emphasizes the role of the
functions of the project, seeks to achieve whole-life value for the project, and relies on the best
judgment of the study team in making final design choices.
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3. PROCESS MAPPING
! Identify components or sub-assemblies for complex products
! Identify primary product functions - expressed as a verb and a noun
! Estimate component or sub-assembly costs and calculate the relative cost of each
! Estimate the value of each component
! Calculate the cost of each function and evaluate the relative cost of all functions
! Investigate improvements
WHEN
WHERE Place Time
Site
Roles Form
Functions
Client/ State Variables
Customers KPIs
WHO
Players Inputs,Outputs
Stakeholders
Transformations
Purpose, Physical system Models
Needs,
Targets Decision,
Vision HOW
Resource Alternatives Criteria
WHY Success
Control,QA
Value engineering benefits
! Proactive result-oriented methodology that "adds value" to products and services.
! Provides high Returns On Investment (ROI) and Reduces capital and life cycle costs.
! Provides "performance / productivity / quality" improvements.
! Reduces time to market / improves project schedules.
! Provides a step change rather than just an incremental change in business.
! VE methodology provides the tools and creates an environment for project teams to find
creative and cost effective solutions to complex technical and organizational problems.
! Improves management’s decision-making capabilities by presenting alternative solutions to
a problem. Effective means to promote and manage change within an organization.
! Powerful team building process and creativity tool. Conditions participants to think,
“outside-the-box.”
! Excellent alignment tool between customer’s needs and the design teams.
! Teaches how to do the "right" job, TQM helps to do the job "right”
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4. PRO/ENGINEER
Pro/ENGINEER is a parametric, integrated 3D CAD/CAM/CAE solution created by
Parametric Technology Corporation (PTC). PTC was the first to market parametric, feature-
based, associative solid modeling software.
There are three basic Pro/ENGINEER design steps from conception to completion:
! Part creation
! Assembly creation
! Drawing creation
We can use Pro/ENGINEER to create a complete 3D digital model of the products. The
models consist of 2D and 3D solid model data which can also be used downstream in finite
element analysis, rapid prototyping, tooling design, and CNC manufacturing. All data is
associative and interchangeable between the CAD, CAE and CAM modules without
conversion.
2D drawing using Pro/E 3D Model using Pro/E
Case Study (Improving product efficiency using Pro/ENGINEER )
About Client: Our Client is a leading multi billion dollar global furniture manufacturer, with
more than 500 product lines, more than 15,000 employees worldwide,
manufacturing facilities in over 50 locations and more than 900 dealer
locations around the world. They have a comprehensive portfolio of
furniture and furniture systems reconfigurable architectural, technology and
lighting products.
Business Need: Globalization, Changing demographics and Technology are changing
consumer base rapidly increasing. This creates huge demand but not
necessary for the same product at the same price tags. These forcing
companies think differently and re look at their cost and create product that
meet needs of market and trends.
Project Scope: Scope was to build CAD model by Reverse engineering of physical Chairs
using Pro/ENGINEER. This includes Concept design, Detail design,
Analysis and Optimization, Digital prototyping and Product lifecycle
management.
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5. Client
Challenges: Client was having approximately 22 different Chairs configurations.
Actually these ware acquired by different companies. Clint was not
having Part and Assembly CAD models. And BOM of these
configurations were not properly stored and organized.
Client’s biggest challenge was to Categorize, Configure and Design these
chair models on CAD platform. Because of not having the proper
controlled CAD data client was facing the below problems.
1. Difficulty in product development and Design change
2. Difficulty in coordinating with the vendors
3. Coordinate with Shop floor
4. Increased complex inventory
5. Difficulty in servicing
6. Configuration of the Standard parts
How ITC
helped: Initially client asked build CAD design model for 6 styles by Reverse
Engineering of physical chairs. This was just reproduction of existing
components in CAD by means of scanning and measuring and building
models using Pro/E. We studied and analyzed configuration of all the
available styles.
We identified a potential for Value Engineering by inducting 16
unplanned styles (Existing designs available with customer) into the
project and eliminating the remaining designs which were mostly
redundant. Our knowledge based engineering solutions and engineering
initiatives will enable our customers to improve productivity and improve
re-use.
We thought of modularity in some of the mechanism like Backrest
mechanism, Height adjustment mechanism, Spider wheel mechanism.
Backrest (J-bar) Assembly
Height Adjustment Mechanism
Spider wheel Assembly
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6. Business
Benefits: We believed in providing innovative value-based solution to our clients.
Our client benefited immensely by out sourcing, not only labor arbitrage
as primary goal. While we are enable our partner to improve on process,
quality and capabilities. We have full set of product engineering lifecycle
capabilities, delivery capabilities and cutting edge collaborative R&D
methods.
! Resulted in modularity in configuration
! Proposition of alternate materials resulted in reducing cost and weight (6
– 7%)
! Reduction of cost on inventory by eliminating the part varieties and also
resulted in increased space utilization by almost 50%
! Improved service quality as spare parts are available mostly off the shelf
which earlier involved Manufacturing lead times
! Manufacturing lead time is eliminated
! All the 22 designs were automated using design automation which
brought down the design time by more than 40%
! Reduced time to search for the Parts and Assembly
! Drive down the cost of the product and its development
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7. ITC Infotech
ITC Infotech is a fully owned subsidiary of ITC Ltd, a diversified business conglomerate. ITC is
one of India’s foremost private sector companies and runs market-leading businesses in
multiple segments. ITC completed 100 years of leadership in 2010.
ITC Infotech is a global IT services and solutions company. The company focuses on
developing industry specific solutions aimed at client’s unique business requirements and
challenges in critical performance areas. ITC Infotech has also established technology Centers
of Excellence (CoEs) to deepen capabilities and incubate cutting-edge technical
competencies.
A robust outsourcing model, comprehensive suite of differentiated solutions, and focus on
excellence in execution, have provided ITC Infotech a leadership position in its chosen
domains. The company is working with a bevy of Fortune listed global customers and its
service delivery footprint spans five continents, spread across 140 countries.
To contact our subject matter experts, please write to: contact.us@itcinfotech.com
www.itcinfotech.com
Global Locations
North America: New Jersey, New York, San Jose, Houston, Troy, Bentonville
EMEA: Milton Keynes, Copenhagen, Prague, Johannesburg
Asia Pac: Kolkata, Bangalore, Victoria, Singapore
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