Use value analysis method to identify needed product improvements for your assig

Question

Use value analysis method to identify needed product improvements for your assigned product, use the following template to establish this analysis.

(Product Name: Dishwasher)

Competitor’s Design

Importance to Customer

Priority for Redesign

LO4: Product Cost [Weight: 1.5%]

Determine the cost of a machined component in your assigned product using the following questioner template:

Question

Answer

From what material is the component to be machined?

What type of machine is used to manufacture the component?

What are the major dimensions of the component?

How many machined surfaces are there, and how much material is to be removed?

How many components are made?

What tolerance and surface finishes are required?

What is the labor rate for machinists?

Competitor’s Design

Importance to Customer

Priority for Redesign

Explanation / Answer

Component Function Competitor’s Design Importance to Customer Cost (INR) % Priority for Redesign Dishwasher A Dishwasher distributes the detergent solution to the entire surfaces of the dishes / utensils and then directs the flow of water to the entire surfaces of dishes/utensils so that soil is loosen and removed. Competitor's design facilitates faster cleaning of dishes / utensils by 20% 1. Cleaning is perfect. Top 3 models in New Delhi costs are as follows : Cheapest among these 3 is cheaper than our product by 20% Redesign should ensure that without compromising on functional aspect where quality of service is taken care off time to clean is reduced significantly so that product becomes functionally better than the competitor's product and alternate material and process to manufacture is there to enable price reduction by 20% 2. Cleaning action is faster. A. Siemens INR 32499.00 3. Cost is lowest B.Bosch INR 30788.0 C. Neptune IFB INR 32899.00 Question Answer Question Answer Question Answer Question Answer From what material is the component to be machined? SS316 (It is a stainless steel where major non iron components are Chromium 16% , Nickel 10% & Molybdenum 2% to resist corrosion) What are the major dimensions of the component? The major dimensions are the length which is 20 mm & diameter which is 10mm How many components are made? Since we are making 200 dishwashers everyday and in one dishwasher one such component is used we make 200 components daily. We do not keep inventories of finsihed components. We use universal lathe machines which are not dedicated to only one type of components so multiple parts can be machined on these. What is the labor rate for machinists? For Sawing , Planning/ Shaping & Turning the labour rate is 200 INR/Hour and for surface grinding it is 400 INR/hour What type of machine is used to manufacture the component? Since we have selected the cylinderical component the major machines required are Universal Lathe Machines , Saw Machine, Planners/Shapers & Surface Grinders How many machined surfaces are there, and how much material is to be removed? There are 3 surfaces the circular cylinderical surface the lower flat surface and upper flat surface What tolerance and surface finishes are required? Since the cylinderical surface is not a mating part we keep a tolerance of +-1 mm and surface roughness of 6.3 micro meter since we are using a normal turning process for material removal & finishing . Both upper and lower flat circular surfaces are mating surfaces so here tolerence will be +-0.02 mm and surface roughness will be 0.2 micrometers as here we are using sawing , planning / shaping & surface grinding for material removal and finishing . Now using above template cost of each component can be found as follows : Component Dimensions 20 mm length & 10 mm diameter For turning operation on cylinderical surface we will add 2 mm & for sawing , planning / shaping & surface grinding operations we will add 2 mm on each upper & lower surface so effective length will be 24mm So length of the component is 24 mm & Diameter is 12 mm. So radius is 12/2=6 mm. For calculating component weight density is required for SS 316 it is 8 grams / cubing centimeters. Component Weight Volume X Density = PI X Square of radius X Height/length X Density = 22/7*6/10*6/10*22/10*8 = 19.91 grams Curent price in India is 210 INR per kg approximately so material cost = 19.91 * 210= 4.181 inr per pieces 4181.1 Now supposing or sawing , planning shaping & turning of 200 pieces if it takes 2 hours and for grinding upper and lower surfaces takes 4 hours then labour cost will be (200*2 +400*4)/200=10 INR per piece Now total cost will be 4.18+10 = 14.18 INR

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