Value engineering


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Value engineering

  1. 1. A Management Perspective<br />Value EngineeringA Case Study of the Indian Railways<br />Chandan Vichoray<br />BE, MBA, Doctoral Thesis Submitted<br />
  2. 2. Introduction<br />A Systematic Method to improve the value of goods or products and services by using an examination of a function<br />Value is the ratio of function to cost<br />Value can be improved by:<br />Improving the function<br />Reducing the cost<br />
  3. 3. Types of Values<br />There are Four Values:<br />Use Value<br />Cost & Exchange Value<br />Esteem Value<br />Scrap Value<br />
  4. 4. The General Value Engineering Job Plan<br />Following steps are generally followed:<br />Information Gathering<br />Alternative Generation<br />Evaluation<br />Presentation<br />
  5. 5. The Indian Railways Case Study<br />The Value Engineering Project was carried out at the Central Railway Electric Locoshed (ELS) Ajni.<br />Problem identification was done based on resource utilization focussed on Use Value and Cost Value<br />The Process involved redesigning of the Journal Bearing Lubrication Pump mounted on the Axle Shaft<br />
  6. 6. Basics<br />
  7. 7. Basics<br />
  8. 8. Basics<br />
  9. 9. Basics<br />
  10. 10. Problem Definition<br />The GITH or the Gear in Two Halves is a part of the Pinion – Gear arrangement wherein the gear is the GITH which drives the pinion as the train starts<br />The Pinion actually drives an Oil pump gear assembly which is submerged in a sump of Oil<br />This assembly provides for a thin film lubrication to the Journal Bearings mounted on the Axle Shaft of the Locomotive<br />This lubrication keeps the friction away and also cools the wheel parts while the train runs<br />Failure of this assembly results in seizures which can prove fatal for the train more so if it’s a passenger train leading to a derailment<br />
  11. 11. Digramatically<br />
  12. 12. The rise of the problem<br />Breakage of the Gear in Two Halves (GITH) mounted on the Axle Shaft due to Impact Loading<br />Changing GITH involved:<br />Dismantling the body<br />Removing the Central Transformer<br />Removing the Traction motor of the affected Axle Shaft<br />Changing the GITH<br />Again Assembling the aforementioned parts<br />
  13. 13. The Management Angle<br />Involved 8 people plus a dedicated Gantry for lifting the Central Transformer, Traction Motors and other parts<br />Required a total of 192 Man hours to change a small part<br />Occupied Pit line for only this work for 24 hours<br />Increased downtime of the Locomotive<br />
  14. 14. Alternatives<br />Initially a study of the design of the system was carried out<br />It was found out that multiple procedures resulted in the fault<br />
  15. 15. Alternatives<br />Initially a study of the design of the system was carried out<br />It was found out that multiple procedures resulted in the fault<br />Based on the kind of problems the various solution alternatives were found out<br />
  16. 16. The Identified Problems<br />The Basis of design was changed<br />Weight of the Pinion<br />The Oil Pump Gear Shaft<br />Non-Standard Specifications<br />
  17. 17. Design Basis Problem<br />The Basis of design was changed<br />The Pinion in this case is the driven gear<br />The Hardness of the GITH was less than that of the Pinion<br />The GITH was the hardest to change<br />
  18. 18. Design Basis Problem Solution<br />The Basis of design was changed<br />The GITH was the driving gear hence the design process was based on GITH<br />The Hardness of the GITH was made more than that of the Pinion<br />
  19. 19. Pinion Weight<br />The Weight of the Pinion was one of the big hindrance<br />Face width of the Pinion was broader contributing to the weight gain<br />Broader face width was foreseen as a solution to proper meshing on turning tracks<br />The weight acted on the Gear shaft of the oil pump gear<br />
  20. 20. Pinion Weight Solution<br />Weight of the Pinion was reduced by reducing the face width based on historical data<br />Suggested on the use of Teflon material for manufacturing the Pinion to further reduce the weight<br />
  21. 21. Oil Pump Gear Shaft<br />Oil Pump Gear Shaft was tapped for screwing the shaft on to the pinion on the taper side<br />The material clearance between the internal threading and key way was very less<br />The less clearance was responsible for the breakage of the Oil pump shaft leading to impact loading on the GITH due to Pinion<br />
  22. 22. Digramatically<br />
  23. 23. Oil Pump Gear Shaft Solution<br />Suggestion was given to change the type of threading from an internal threading to an external threading on an extended screw as a part of the Oil pump gear shaft<br />Securing the OPGS with a castle nut so as to ensure zero play during meshing<br />
  24. 24. Digramatically<br />
  25. 25. Non-Standard Specification<br />All specifications are non standard considering the manufacturing done by GEC Alsthom.<br />Parts with such specifications are difficult to manufacture in local units<br />Leads to productivity delays as sourcing has to be done from the OEM<br />Costlier Proposition<br />
  26. 26. Thank You<br />