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2007 CSVA Conference > Manufacturing
Author : Jean-René Gagnon, Process engineering Lead and Patrice Quintin, P.Eng, Mechanical engineering lead
Description : The presentation highlighted how PryoGenesis, a world leader in the design, development, manufacture and commercialization of advanced plasma processes, worked with McGill University's Value Engineering Program. PryoGenesis fabricates plasma torches which are in high demand as they use clean electricity to generate high temperatures, replacing the use of fossil fuel torches.  PryoGenesis submitted the optimization of a Gas Cabinet and a Cooling Skid to the McGill Value Engineering program. The Value Engineering study by McGill University engineering students resulted in optimization of the fabrication of the Gas Cabinet and Cooling skids. The students brought new ideas and current knowledge to the project, PryoGenesis brought engineering experience to the study. 
Author : Shyam Gupta, CVS-Life
Description : VE/VA, when applied as per the recommended steps, is known to improve performance (Function) and reduce the cost of the product  at the same time. It also helps in solving problems that the customers are reporting. The case study “Front Fender” is a live example which illustrates this very clearly. 

This case study was taken up by the team to study and resolve a warranty problem in the most popular motorcycle in India at that time. The bike called CD100 was being manufactured in India by M/S Hero Honda Motors Ltd – now Hero Motocorp Ltd. This was a joint venture of the world leader M/S Honda Motors Ltd, Japan and the largest maker of bicycles in the world called Hero Cycles Ltd of India. Since this model created a revolution in India because of its fuel efficiency and comfortable riding, a warranty complaint was a blot on the company and created customer dissatisfaction.

The team worked tirelessly and presented the case study to the top management which consisted of directors and senior officers of both companies. The recommendations were sent to Honda R&D which is the ultimate body to approve the design changes. They studied the proposal and accepted. Thus, the warranty problem was completely solved resulting into increased customer satisfaction. At the same time the cost of the front fender to the company was reduced by 27.6% which is significant.

Author : Sebastian Meindl, PVM, TVM, CVS®
Description : This presentation highlights he history of VA/VE in Germany, the implementation of VA/VE in the Association of Engineers and typical application of the methodology, particularly in manufacturing.  Many different industrial examples highlight the impact of the application of VA/VE in industry and manufacturing. VE in Germany is primarily applied in the industrial space and there is strong support within the Association of Engineers for VE. 
Author :
Description : Outlines why Value Analysis is important to manufacturers. In order to harness innovation, a systematic and replicable problem solving method is essential. Value Analysis/Value Engineering is such a problem-solving method.
Author : Sandy Munro
Description :
Author : James D. Bolton, PE, CVS, PVM
Description : An effective way to successfully apply Value Engineering (VE) principles in manufactured products and processes is to utilize TRIZ in combination with Design for Manufacturing and Assembly (DFMA).
Author : Samaher Chekir, Director R&D, Kik Consumer Products Group
Description : The presentation shows the process and the results of a value analysis workshop, which took place at Lavo regarding dish detergent. This first experience with VA allowed Lavo to identify cost reductions that were important to maintain the company’s competitiveness.Lavo is a company from the Kik Consumer Products Group.
Author : Pierre Marquis, Sanmina SCI
Description :
Title : VE, Lean and Six Sigma Synergy (PDF | 2014 | MEMBER-ONLY | #421)
Author : Dr. Michael Mladjenovic, P.Eng., Master Black Belt, Lean Sensei, The Sensei Group
Description :

In today’s rapidly changing, complex, and global environment, the ability to create value through innovative products and services, faster and more profitably than competitors is a matter of survival and sustained success. That goal and objective of sustainable value creation and retention can be achieved only by implementing simultaneously  Value Engineering, Lean and Six Sigma methodologies that share common scientific methodology based Structure.

This session will highlight key characteristics of development and implementation or Organizational Excellence architecture based on integration of Value Engineering, Lean and Six Sigma methodologies and tools.
Author : Prasad V. Rayasam
Description : This paper discusses how design for manufacturability can result in creating a lower cost product to meet all performance targets. Integration and collaboration between design and manufacturing teams result in questioning legacy product features and developing new ones that meet performance & manufacturing criteria. In this paper we discuss one specific example of design for manufacturing of airfoils for modern day Turbines. Generation of 5-axis CAM toolpath for airfoil machining is a complex process. There is high value in designing “manufacturable” or producible airfoil CAD models at the design phase to ensure reduced rework to fix geometry inconsistencies during the manufacturing phase. We discuss common issues faced during machining of airfoils and how they can be mitigated with better airfoil design in conceptual design phase. Though authors did not explicitly follow SAVE recommended value engineering steps during the execution of this project, in hindsight, the mindset required and employed by entire global team was no different than the spirit of value engineering. 
The main challenge faced in creating such mindset is many times lack of awareness and in-depth knowledge of design requirements by manufacturing engineers and lack of manufacturing constraints and cost functions by design engineers. One of the important enablers for breaking these barriers between design and manufacturing is CAD-CAM framework. What we learnt is the need for same set of tools or seamless integration of tools that is transparent to users in both communities and also need for “real time” feedback during design of features. An analysis was carried out of common problems faced during airfoil machining which are attributable to geometric inconsistencies. Algorithms were built to identify these geometry inconsistencies. These algorithms were used by preliminary airfoil designers to fix the identified problems in design phase. A steam turbine blade that was manufactured at GE Power business is used for this study. The results helped identify the airfoil geometric inconsistencies upfront and avoidance of re-work and failed toolpath creation during airfoil machining in the shop, resulting in several thousand dollars of benefit. Equally importantly, the process followed especially building an inter-disciplinary global team of design engineers and supply chain engineers/machinists has proven to be a best practice that is being replicated for other projects.  
Author : K S Deep
Description : Bottoms up should cost enables corporations to better understand cost structure of their product. For should costing to be trust-worthy and useful, a validated cost model is mandatory. A bottoms up should cost model is comprised of components like material, machine, process, and cost algorithm. In order to validate models, one needs to validate all these components to match the physics of the process and rates applicable for the particular organization or region of manufacture. Due to innumerable variables involved and lack of well-defined baseline data, validating a cost model is very challenging. In this study we present a systematic and physics based approach that can be adopted by organizations to validate should cost models. We discuss the process and challenges involved in doing such a validation and showcase key use-cases of a validated should cost model during sourcing negotiations and design to cost studies.
Author : Joseph Otero
Description : The Value Methodology is employed to solve different kinds of problems of varying levels of difficulty, so the tools employed and the associated rigor should match the problem. The tools and rigor of the Value Methodology should fit the problem or opportunity. For example, a three-day VE event with cursory style tools may be perfect for conceptual design work whereas a set of multiple six-day VE events employing tools that demand rigor may be needed for addressing final design challenges. This presentation makes general recommendations about what tools in the value methodology to employ in specific circumstances.