bulbholder
DESCRIPTION
TRANSCRIPT
Value Engineering of Plastic bulb holder
Course: Value Engineering
Faculty: Mr. Jayanth Murthy
Date: 8th to 12th August 2011
Team Members:
Alomi Chishi, Ankur Gupta, Jaskeerat bedi,
Madhumanti Ghosh, Subhash Chandra Gupta,
Vaibhav Vyas
Batch:
Post Graduate Diploma Program in Design, 2011
Discipline:
Strategic Design Management, Semester III
Institute:
National Institute of Design, Gandhinagar, India
Table of Content
Introduction …………………………….. 01
Project
Project selection phase………………………. 02
Information Phase…………………………….. 03-06
Function Phase………………………………... 07-08
Creative Phase………………………………... 19-13
Analytical Phase……………………………….. 14-16
Evaluation Phase………………………………. 17
Recommendation Phase……………………… 18-19
contact
Introduction
Value engineering (VE) is a systematic method to improve the "value" of goods or products and services by using an examination of function. Value, as defined, is the ratio of function to cost.
It is a primary tenet of value engineering that basic functions be preserved and not be reduced as a consequence of pursuing value improvements.
Value= Functioncost
8/12/2011 1
Product chosen :
‘Plastic Bulb Holder’
Manufacturer : Local
MRP: Rs 8:00
Colour : Black
Description : Outer body is injection molded , made
out of plastic (bakelite) and two bronze electrical
connectors to connect to the electricity.
The plastic bulb holder is a medium to mechanically
support a bulb and to make electrical contact.
Project Selection Phase
8/12/2011 2
Exploded view‘ Plastic Bulb Holder’
Information Phase
8/12/2011 3
Bill Of Material
Sr No. Component Material Qty. Cost
Total Mat. Mfg
1 Main body Plastic (Bakelite) 1 1.54 1.04 0.5
2 Cover Plastic (Bakelite) 1 0.82 0.52 0.3
3Electrical
Connector(Body)
Bronze 2 0.46 0.16 0.3
4Electrical connector
(Screw)Bronze 2 0.18 0.08 0.1
5 Ring Plastic (Bakelite) 1 0.59 0.39 0.2
6 Spring Steel 2 0.14 0.04 0.1
8/12/2011 4
Material map of bulb holder
8/12/2011 5
No Segment Stated Expectation
Implied Expectation
1 General Hold the bulbfirmly
Affordable
Durable
Safe
Good connectivity
2 Engineer Manufacturability Material safety
TechnicalFeasibility
Good insulation
Cost Effective Production
3 Manufacturer
Saleable Material Economy
Cost Effectiveness
Profit Labour Economy
Production friendly
4 Distributor Easy to ship Easy availability
Durable-no breakage in transit
No Segment Stated Expectation Implied Expectation
1 Seller/Shopkeeper/Vendor
Profitable High Demand
2 User Workable Material safety
Durable Good insulation/Connectivity
3 Junk Dealer Recyclability
Selling Components
4 Environment Biodegradable Pollution free production
Non-toxic
Expectation Analysis of Various Segments
8/12/2011 6
Main BodyCover Ring
PinMaterial: brass
Material : Bakelite
Function Phase
8/12/2011 7
Sr.No
Component Cost
Primary Function Secondary FunctionWorth
[W]V-I-P
Basis of identifying
VIP
Benefitof change
Verb noun Verb Noun
1 Main body 1.54 Holds Bulb Holds Terminals 1.34 0.20Material can
be reduced in the body
Material cost isreduced
2 Cover 0.82 Cover Terminals Guides wire 0.72 0.10Material can be reduced
Material cost isreduced
3ElectricalConnector
Body0.46 Transfer Electricity Holds Spring 0.46 0
4ElectricalConnector
Screw0.18 Attach Wire 0.18 0
5 Ring 0.59 Lock Cover Complete Form 0.59 0
6 Spring 0.14 Provide Back force Transfer Electricity 0.14 0
Function-Cost-Worth-Value Improvement Potential Analysis
8/12/2011 8
Bakelite Brass
Main body (8gm) Cost % - 41.28%
Bakelite Qnty - 1
Cost of manufacturing - 0.5
Cost of material – 1.04
Provide Support for bulb. Holds Pin.
Cover (4 gm) Cost % -21.98%
Bakelite Qnty – 1
Cost of manufacturing – 0.3
Cost of material – 0.52
Cover Brass terminal. Guides Wire.
Ring (3 gm) Cost % -15.81%
Bakelite Qnty – 1
Cost of manufacturing – 0.2
Cost of material – 0.39
Provide Support for Lamp Shade.
Cost of manufacturing - 1
Cost of material - 1.95
Pin (Body) 2 gm Cost % -12.33%
Brass Qnty – 2
Cost of manufacturing - 0.3
Cost of material – 0.16
Transfer electricity to the Bulb.
Screw (1 gm) Cost % - 4.82%
Brass Qnty – 2
Cost of manufacturing – 0.1
Cost of material - 0.08
Attach Wire to the Pin.
Spring (0.5 gm) Cost % - 3.75%
Bakelite Qnty – 2
Cost of manufacturing – 0.1
Cost of material - 0.04
Provide back force to the bulb so that ensures locking.
Cost of manufacturing - 0.5
Cost of material - 0.28
Cost of manufacturing - 1 .5Cost of material - 2.23
8/12/2011 9
8/12/2011 10
Creative phase
8/12/2011 11
Creative phase
Design 1- INTEGRATED BATTERY within BULBHOLDER
Adding Function of an integrated battery, that gets charged with heat/light energy produced by the bulb, when connected via electricity. If the electricity goes off, the battery gets activated and the bulb is switched ON .
Though the cost of the bulb holder increases, the function of the bulb holder increases many times. Houses that have power cuts up to 8 hours may consider replacing for this design.
Material used for the new design will be better, better technology
8/12/2011 12
Creative phase
Design 2- MINIMALIZED material
Value can be increased if we reduce the material of Brass and spring used in the bulb holder. This can be achieved if re-design the plate inside the holder, closer to the bulb. Also the bulb is interlocked by threading. The number of threads can be controlled and reduced.
This design will use lesser material and better interlocking techniques.
8/12/2011 13
Creative phase
Design 3- SAFE DESIGN
The most important aspect of a bulb holder is that it should be safe for uses to use.In our third option, we use superior quality material and complex design using magnetic plates, that will ensure easy & safe usage for wiring and attaching the bulb.
Superior Material, durable product & ease of use
8/12/2011 14
Creative phase
Analytical Phase
8/12/2011 15
Attributes
grip/locking mechanism (A)
material (B)
safety ( c)
durability (D) connect
ivity (E)
affordability (F)
ease of use (G)
grip/locking mechanism (A)
x A2 C4 A2 A1 E1 A4 A2 11
material (B) C4 B1 D1 E4 F2 B2 3
safety ( c) C4 C1 E1 C4 C4 21
durability (D) E4 D2 D4 7
connectivity (E) E4 E4 18
affordability (F) F2 4
ease of use (G) 0
Evaluation phase
Design
A/11 B/3 C/21 D/7 E/18 F/4
Design 1(batteryaided)
33 9 63 21 90 12 228
Design 2 (minimized)
55 9 21 21 54 20 180
Design 3 (magnet)
33 15 105 35 54 4 246
8/12/2011 16
Recommendation phase
8/12/2011 17
Recommended Design 1
• A battery aided LED light attached
• Increases functionality
• Does not require change in the original form of
the product
Recommendation phase
8/12/2011 18
Recommended Design 2
• Magnet plate for attachment
• Reduce the size of the product considerably
• This will make the product highly safe
• The bulb changing process will be much more
easier
contact
For any queries:
Alomi Chishi: [email protected]
Ankur Gupta: [email protected]
Jaskeerat Bedi: [email protected]
Madhumanti G: [email protected]
Roli Agarwal: [email protected]
Subhash G: [email protected]
Vaibhav Vyas: [email protected]