Value Engineering
During the lifecycle of a particular product, companies tend to review the existing design to look out for ways to reduce production cost. Even when coming up with a new product, so many manufacturers go for analyzing the same during its design phase so that it requires an optimum level of cost to produce. This is where Value Engineering comes in. Value engineering is an organized method to improve the “value” of a product or service in the lowest of cost. VE is a systematic approach aimed at obtaining the necessary functions in a product, process, or system at the minimum overall cost, thereby maintaining the quality, reliability, performance, and safety. It provides the substitution of materials and methods with less expensive alternatives, without jeopardizing the functionality. It is emphasized totally on the functions of various components and materials, rather than their physical characteristics. Value engineering is also called value analysis. It was Lawrence Miles who came up with the concept of finding substitute materials for parts unavailable. It was found that substitutions not only reduced cost but aided in a better-finished product. It was this new technique that evolved into value engineering today. The value in VE means two components: The function of a product is the specific task it was designed to perform, and the cost refers to the cost of the item during its life cycle. The ratio of function to cost denotes that the value of a product can be increased by either improving its function or decreasing its cost. In value engineering, the cost related to production, design, maintenance, and replacement are included in the analysis. If we take an example of a new tech product which is being designed and is slated to have a life cycle of only two years; the product will be designed with the least expensive materials and resources that will live up to the end of the product’s lifecycle, saving the manufacturer and the end-user money. This is how product value is improved by reducing costs. It is evident that with the increase in function value and decrease in price, the overall product value increases. Stages of Value Engineering There are three main stages to value engineering, which are: Benefits of Value Engineering Value engineering helps an organization in numerous ways: Value engineering concepts apply to business as well as technical situations and consequently lead management to informed, result-oriented decisions. Value engineering has to be treated as a future investment for gaining technology leadership in the industry.
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Design Analysis – FEA, CFD, and Mold Flow Analysis
Table of content Finite Element Analysis (FEA) Computational Fluid Dynamics (CFD) Mold Flow Analysis Importance of CAE in design analysis Over the years, the term “Design Analysis” has been essential in the manufacturing sector. Instead of making a prototype and creating elaborate testing regimens to analyze the physical behavior of a product, engineers can evoke this information quickly and accurately on the computer. Design analysis is a specialized computer software technology designed to simulate the physical behavior of an object. If an object will break or deform or how it may react to heat are the sort of queries design analysis can answer. Design analysis helps in minimizing or even eliminating the need to build a physical prototype for testing. As a result, the technology has gone mainstream as a prized product development tool and found its presence in almost all engineering sectors. This article discusses three major design analysis software, namely: Finite Element Analysis (FEA) The Finite Element Analysis (FEA) is a specialized simulation of a physical entity using the numerical algorithm known as the Finite Element Method (FEM). It is used to reduce the number of physical prototypes and experiments and analyze objects in their design stage to develop better products faster. The term ‘finite’ denotes the limited, or finite, number of degrees of freedom used to model the behavior of each element. Mathematics is used to understand and quantify a physical phenomenon such as structural or fluid behavior, wave propagation, thermal transport, the growth of biological cells, etc. Most of these processes are described using Partial Differential Equations. Finite Element Analysis is one of the most prominent numerical techniques for a computer to solve these PEDs. FEA will analyze an object in question by breaking its entire geometry into small ‘elements,’ which are put under simulated conditions to see how the elements react. It displays the results as color- coded 3D images where red denotes an area of failure and blue indicates fields that maintain their integrity under the load applied. However, note down that FEA gives an approximate solution to the problem. FEA is used in problems where an analytical solution is not easily obtained, and mathematical expressions are required because of complex geometries, loadings, and material properties. Engineers also use FEA to reduce the number of physical prototypes, conduct failure investigations and improve component designs. It is also used by forensic engineers to determine stress concentrations in structures and to show alternative designs. Finite element analysis can help analyze fatigue-related failures. Finite element analysis has numerous other applications. Its advantages are many – it enables engineers to make better products faster. By breaking down a complex object into thousands or hundreds of thousands of finite elements, finite element analysis predicts how a given object will respond under a certain load. Furthermore, it helps forensic engineers confirm the stress concentrations in a case and show possible alternatives. FEA is also helpful for fatigue-related failure analysis. Computational Fluid Dynamics (CFD) Computational Fluid Dynamics (CFD) is a specialized simulation that analyzes fluid flows through an object using numerical solution methods. CFD incorporates applied mathematics, physics, and computing software to evaluate how a gas or liquid flows and how it affects an object as it flows past. CFD is based on Navier-Stokes equations which describe how a moving fluid’s velocity, temperature, pressure, and density are related. Aerodynamics and hydrodynamics are two engineering streams where CFD analyses are often used. Physical quantities such as lift and drag or field properties as pressures and velocities are computed using CFD. Fluid dynamics is connected with physical laws in the form of partial differential equations. Engineers transform these laws into algebraical equations and can efficiently solve these equations numerically. The CFD analysis reliability depends on the whole structure of the process. Determining proper numerical methods to develop a pathway through the solution is highly important. The software which conducts the analysis is one of the key elements in generating a sustainable product development process, as the number of physical prototypes can be reduced drastically. CFD is used in almost all industrial domains, such as: With the help of CFD, fluid flow can be analyzed faster in more detail at an earlier stage than by testing, at a lower cost and risk. CFD solves the fundamental equations governing fluid flow processes and provides information on essential flow characteristics such as pressure loss, flow distribution, and mixing rates. CFD injection molding is a widely used manufacturing process for plastic components. It has undergone many improvements over the past few decades, and numerical simulation models enable mold and part design without costly experiments. CFD has become an integral part of the engineering and design domains of prominent companies due to its ability to predict performance of new designs and intends to remain so. Mold Flow Analysis Moldflow, formerly known as C-mould, is one of the leading software used in processwide plastics solutions. Mold flow computes the injection molding process where plastic flows into a mold and analyzes the given mold design to check how the parts react to injection and ensure that the mold will be able to produce the strongest and uniform pieces. Using mold flow analysis, a manufacturer can reduce stress levels in its mold and increase filling and product quality. By assessing the flow of the plastic melt, Mold Flow can make informed design decisions and avoid costly mistakes. This software is an invaluable tool to improve quality and increase productivity. This software is beneficial for manufacturers that need to predict the flow of a mold and determine its feasibility. Two of the most popular mold flow analysis software are Moldflow and Moldex3D, used exclusively by many mold makers. There are three types of Mold flow analysis which are as follows: To simulate mold flow, a network of rectangular elements is discretized on the mold. The corresponding velocity field is then used to calculate the flow of the melt. A two-stage predictor- corrector method, developed by Hieber and Shen, has been used since then. Mold makers typically use the software
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Geometric Dimensioning and Tolerancing (GD&T)
The design model is a depiction of a part design. However, the design model can never be an accurate representation of the product itself. Due to shortcomings in manufacturing and inspection processes, physical parts never match the design model exactly. An essential aspect of a design is to specify the lengths the part features may deviate from their theoretically accurate geometry. It is vital that the design intent and functionality of the part be communicated between the design engineers and the manufacturing unit. It is where the approach of GD&T comes into play. Geometric dimensioning and tolerancing or GD&T is a language of symbols and standards used on engineering drawings and models to determine the allowable deviation of feature geometry. GD&T consists of dimensions, tolerances, definitions, symbols, and rules that enable the design engineers to convey the design models appropriately. The manufacturing unit uses the language to understand the design intent. To master GD&T, one needs to understand the crucial concepts, which includes: GD&T is an efficient way to describe the dimensions and tolerances compared to traditional approximation tolerancing. The engineer might design a part with perfect geometry in CAD, but the produced part, more often than not, turns out to be not accurate. Proper use of GD&T improves quality and reduce time and cost of delivery by providing a common language for expressing design intent.
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What are DFMA and DFMEA
Table of content Design for Manufacturing and Assembly (DFMA) Design Failure Mode and Effect Analysis (DFMEA) During the last few decades, manufacturers have been able to source parts globally with the developments in technology. More and more manufacturers have entered the competition as it grows fierce. Companies in developing nation markets offer products at lower prices. To sustain business and achieve growth, many manufacturers are developing new products to cater to the consumers and widen it. They must be very marketable and of high quality. The Design for Manufacturing and Assembly (DFMA) method enables firms to develop quality products in lesser time and at lower production costs. Design for Manufacturing and Assembly (DFMA) Design for Manufacturing and Assembly or DFMA is a design process that targets ease of manufacturing and assembly efficiency. Simplifying the design of a product makes it possible to manufacture and assemble it in the minimum time and lower cost. DFMA approach has been used in the automotive and industrial sectors mainly. However, the process has been adopted in the construction domain as well. DFMA is a combination of two methodologies which are: DFM and DFA seek to reduce material and labor costs associated with designing and manufacturing a product. For a successful application of DFMA, the two activities should operate in unison to earn the most significant benefit. Through the DFMA approach, a company can prevent, detect, quantify, and eliminate waste and manufacturing inefficiency within a product design. Design Failure Mode and Effect Analysis (DFMEA) Design Failure Mode and Effect Analysis (DFMEA) is a systematic string of activities to identify and analyze potential systems, products, or process failures. Design Failure Mode and Effects Analysis or DFMEA focuses on finding potential design flaws and failures of components before they can significantly impact the end users of a product and the business distributing the product. The design failure mode and effect analysis – DFMEA is an ideal process for any sector where risk reduction and failure prevention are crucial, which includes: With expertise in advanced engineering, Prescient Technologies ensures maximum benefit to their client in terms of value addition, weight reduction, material selection, cost reduction, or manufacturing process selection. Visit our website for more details or send a message.
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Product Tear Down Analysis
Table of content What is a product teardown? Material Selection Responsibilities of a product teardown team Pre-requisites for a product teardown workshop Length of a product teardown workshop Knowledge and product improvement How do you determine procurement costs for product design, materials, and specifications? A superb way to get valuable insights and pinpoint design improvement and cost reduction opportunities is through a product teardown analysis. What is a product teardown? In simple words, the process of disassembling a part to understand how its construction and its functionalities are known as product teardown. This technique helps companies understand their products’ components, manufacturing processes, and cost structures. These data can then be used to develop new concepts. A product teardown process is an orderly way to know about a particular product and identify its parts and system functionality to recognize modeling improvement and cost reduction opportunities. Unlike the traditional costing method, teardown analysis collects information to determine product quality and price desired by the consumers. Companies can understand their competitor’s product, on what ground it differs from their own, and the manufacturing cost associated. The three primary reasons for a product teardown analysis are: Breakdown and Analysis It involves understanding the current technology, functionalities, and components of a product, identifying its strengths and weaknesses, and establishing areas for improvement. Benchmarking Benchmarking establishes a baseline in terms of understanding and representation of the product. It provides a comparison of new conceptual designs. Knowledge and product improvement It involves gaining engineering knowledge to enact new room for concept development. The entire product teardown process can be summed up in five steps: The product teardown study technique has proven to be suitable for obtaining crucial data about the manufacturing method, components, build-up model, functionality, and competitors’ strategies to improve and come up with a more refined version of a product. Material Selection Material selection stands out to be one of the most crucial aspects of engineering design as it determines the design’s reliability in terms of industrial and economic viewpoints. A great design needs appropriate material combinations, or it will fail to be a profitable product. Engineers need to choose the best materials for the same, and there are several criteria they rely upon, such as property and its reaction to given conditions. Some important points to be included are: Mechanical properties: A design needs to go through various manufacturing practices depending on the material. The primary goal is to prevent the failure of the product from a material viewpoint and ensure service fit. The materials are subject to stress, load, strength, and temperature variations. Wear of materials: Most of the time, chances are that materials are contacting each other in a product. It can be seen in the case of gears. The selected materials should be able to withstand wear and tear. Corrosion: This is a condition where the importance of material selection can be witnessed the most. It is evident in products open to the environment for an extended period. Materials like iron are highly prone to corrosion. So it is essential to make that the material is corrosion-resistant and capable of being used for the product. Manufacturing: Although the material is fit to be used for a product, it has to be appropriate for the manufacturing process. Improper machining can lead to a faulty product, and incorrect machining stems from an inability to put manufacturing functions of materials. Cost: Cost is a crucial fact to consider while selecting materials. Certain metals are rare to obtain, considering their availability and lengthy refining process. Although the cost factor can be neglected when performance is given priority, overall associated costs should be considered. There is a reason why plastics have massively replaced metals in the manufacturing process. Responsibilities of a product teardown team The responsibilities of a product teardown team can vary widely depending on the company and the type of product. Some of the most important goals of a product teardown team include: assessing the total cost of manufacturing the product and determining general overhead costs. Other team members’ duties may involve reducing labor and material costs and identifying areas for improvement. Often, a product teardown team will also be responsible for establishing benchmarks and determining where improvements can be made. The product teardown team also consists of people with extensive experience in the industry. This team will help startups evaluate their products and identify critical areas for improvement. By taking apart products, they’ll learn the process that goes into the design of each product and provide evidence-based recommendations to improve its structure. Pre-requisites for a product teardown workshop There are several different product teardown workshops, including the Japanese style, which has been used successfully in Japan since the 1970s. Every major Japanese corporation has adopted this style of workshop. Most western teardown methods focus on visual displays and lack a detailed analysis of products. In contrast, the Japanese process forces participants to examine the product in detail and compare it to its competitors. Marketers and design executives can use the results of this workshop to improve their products. Before you conduct a product teardown workshop, you must be sure to secure your products. If the products are your competitors, you will need to carry out rigorous non-destructive performance testing. Your workshop should also include data recording. Depending on the nature of the workshop, the requirements may vary from one client to the next. Length of a product teardown workshop The duration of a product teardown workshop will depend on the nature of the item being analyzed. Some workshops are as long as four days, while others are shorter, depending on the client’s needs. Participants will learn about all teardown methods and how to implement them in a team workshop setting. Often, these workshops include hands-on, creative teardown of products. But the exact length of a product teardown workshop depends on the number of participants and the types of products they are analyzing. To maximize the workshop’s effectiveness, make sure participants are aware
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