W H I T E P A P E R S

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”.

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.

2Value Engineering

Over viewVALUE ENGINEERING

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

Value Engineering

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”

Time

Form

State Variables

KPIs

Inputs,Outputs

Transformations

Physical system Models

Decision,

Alternatives CriteriaResource

Control,QA

Vision

Success

Purpose,

Needs,

Targets

Players

Stakeholders

Client/

Customers

Roles

Functions

Place

Site

WHEN

WHERE

WHO

WHYHOW

3

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.

Value Engineering

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.

5Value Engineering

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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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

7Value Engineering

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

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