The evolution of dashboard has led to increased vehicle occupant comfort and convenience as new systems become available. The project work aims to develop the work to apply theoretical and practical tools/techniques to solve real life problems related to industry and current research in this project automobile (Car) dashboard upper cover is selected for a design. For doing so conceptual design tool is used. I am created a five different concepts using different benchmarking & brainstorming. Select a best option using different tools in six sigma like trade off analysis. Three-dimensional CAD software (such as CATIA) is used to develop a CAD model same as concept. To reducing variation and improve the quality of processes six sigma DMADV methodology applied to the project. The aim is to achieve the essential function at the lowest overall cost while maintaining customers’ optimum value assurance. In this project I try to develop a such dashboard design which follow a design guidelines, And analyze and discuss the results to Obtain valid conclusions which follows a design Standards.

1. “Material And Structure Optimization And Value Engineering Applied To Car
Door Window Regulator”
A Case Study
Er.Jayesh Sudhakar Sarode
Department of mechanical engineering,
JTM college of engineering, DBATU University
Faizpur, Maharashtra, India
jayeshsarode50@gmail.com
Er.Jayesh Sudhakar Sarode
Product Design Engineer (Interior & BIW)
IKSC Knowledge Bridge Pvt. Ltd.
Pune, India
jayeshsarode50@gmail.com
Abstract -
The evolution of window regulator technology has led to
increased vehicle occupant comfort and convenience as new
systems become available. Manual window regulators, while
still in use, are declining steadily. In this project automobile
window regulator is selected as a case study for the use of
optimization technique in engineering design. This is a project of
the work performed towards the stiffness optimization of an
automobile window regulator. Three-dimensional CAD software
(such as CATIA) enables us not only to define kinematical
relationships but also to investigate free traveling on newly
developed systems. By doing so, potential errors can be
minimized in the design phase, so that the costly prototype
manufacturing can be prepared most favorable. The final result
is a window regulator stiffer.
Car window is one of the main parts which are used as
protection for passengers from side collisions. The aim of the
project is to analyze the car window regulator with presently
used material steel and replacing with composite materials like
Aluminum, Carbon Epoxy, S-glass epoxy, E-Glass epoxy. Also
we are going to reduce weight of the window by using
composite materials replacing with steel. By this we have to
reduce the damage percentage of the car and passenger
protection. In this project, the Car window regulator modeled
using parametric modeling software CATIA. CATIA is the
standard in 3D product design, featuring industry-leading
productivity tools that promote best practices in design. In order
to define, create and communicate ideas and solutions, the
design was modelled in CATIA software to create the final
renders. Once the overall design was defined, materials and
accessories were specified.
This project intends to explore the adoption of Value
Engineering (VE) as a value creation tool. VE relates to a
systematic and multi-disciplinary team approach adopted by
organizations which analyze the functional requirements of new
and existing products, projects or services. The aim is to
achieve the essential function at the lowest overall cost while
maintaining customers’ optimum value assurance. This project
presents the basics of Value Engineering and its different phases
that can be implemented to a window regulator for its
optimization. Value Engineering can improve the product cost
by reducing the unnecessary costs associated with the product. It
explores each part of the Value engineering job plan for the
successful application of the technique. A case study has been
discussed and an analysis has been carried out by this process to
achieve the product optimization. Various tools are used for the
analysis of the product while evaluating the product at different
phases. At the end the results obtained after implementation of
this technique are discussed.
A dramatic reduction in environmental impact can be made by
product remanufacturing in which, in contrast to material
recycling, the geometrical form of the product is retained and its
associated economical and environmental value preserved. Our
long term goal is to postulate and validate design metrics
which effectively and efficiently measure the
remanufacturability of given designs. As well as identifying
existing remanufacturing guidelines, philosophies, and practices.
This project details out the analysis of the existing
structure and identifies the drawbacks and explains the process
of window system design. Designer from an automobile
engineer faces so many different problems during their work.
Some of the major problems in automobile window are taken as
problem for this project and those problems like high weight,
high cost, excessive reinforcements, and water leakage.
The study of manufacturing is very important in order to
ensure that student understand on what are the needs to do in this
project. To establish the requirements for the design, initial
studies were performed a literature review, a benchmark of
related products and a study of standard car window designs.
After this the final requirements were defined and the concept
generation design phase was begun. In this phase a number of
design methods were applied. The design concepts were
systematically evaluated in respect to if, and to what degree, the
concepts met the defined demands and needs of the design. The
final concepts were completed with the demands of the company
to obtain the results.
This project is about designing and applying value
engineering to the Car Door Window regulator.
Keywords- Car Door Window Regulator; Value
Engineering; Value Analysis; Material Optimization;
Structure Optimization
I. INTRODUCTION
1.1 WINDOW REGULATOR (PRE-STUDY)
What Is a Window Regulator?
• Window regulators are found in vehicle doors and
are used to lower and raise the car windows.
• One of the standard properties of cars is the
capability to open windows of side doors. As a result, the
need of a device that opens windows of car doors arose
with the invention of cars. This device which is used to
raise or lower the window of the car door is called a
window regulator.
• Window regulators are components that make it
possible to lower and raise the window glass in a vehicle.

2. The power window system allows each of the door
windows to be raised and lowered electrically by actuating
a switch on the trim panel of each respective door.
They are one of the most commonly used parts
of the car, since people are always lowering or raising their
windows. Because their continued use, window regulators
are prone to wearing down and breaking. A window
regulator can be manually operated by a hand crank or
power operated by an electric motor. Window regulators
use either a cable or a gear to expand or retract the
mechanism.
Power window regulators may be equipped with
an option specific to the vehicle such as “Anti-pinch”
and/or “1– touch“ feature.
Anti–pinch: This feature prevents an object from
becoming lodged or pinched by the window. If an object is
preventing the window from completing the up cycle the
regulator senses the obstruction and reverses the window.
1-touch: This feature allows the operator to either
raise or lower the window by pushing a control once
instead or holding it for the full cycle. The instillation of a
window regulator (manual or power) requires the removal
of the door interior trim panel. The removal of this panel
often causes damage to the retaining clips, handle bezel or
even the vapor barrier.
The evolution of window regulator technology has
led to increased vehicle occupant comfort and convenience
as new systems become available. It also offers a growing
opportunity for the independent Aftermarket. Manual
window regulators, while still in use, are declining
steadily. At the other end of the technology spectrum, the
most advanced electronic units feature one-touch comfort
function and anti-pinch* operations.
Types of Technology
Powered window regulators are supplied in four distinct
technologies, each employing a slightly different method
to achieve a similar result:
Cable System
 Cable these days is a marginal technology, used
mainly in rear doors and industrial vehicles
 Cable attached to one side of the slider, making it
more efficient in one direction
 Used mainly on hgvs and older vehicles
Bowden System - this is the most commonly used
technology
this is the most commonly used technology
Cable attached to both sides of the slider
Used mainly on 4 or 5 door vehicles and rear windows
where the glass is smaller
Double Bowden System
Double Bowden – the latest and most innovative
technology
Similar to the Bowden system but uses two sliders
allowing large windows to be raised or lowered evenly
Used mainly on 3 door vehicles and front doors
Scissor System
Scissor – used predominantly in Japanese and Vauxhall
vehicles
A motor operates a gear wheel to raise and lower the
window using a scissor action
Fitment within doors can be problematic compared
with Bowden systems

3. Types of Window Operation
Manually Operated
Power Operated
1.2 VALUE ENGINEERING (PRE-STUDY)
I. INTRODUCTION
Value Engineering is a technique for determining the
manufacturing requirements of a product/service; it is
concerned with its evaluation and finally the selection of
less costly conditions.
VE is a process for achieving the optimal result in a
way that quality, safety, reliability and convertibility of
every monetary unit are improved.
Value Engineering is usually applied in the analysis
and design of a service/product.
In fundamental terms, VE is an organized way of
thinking or looking at an item or a process through a
functional
Is an intensive, interdisciplinary problem solving
activity that focuses on improving the value of the
functions that are required to accomplish the goal, or
objective of any product, process, service, or organization?
What Is Value ?
Value is the lowest price you must pay to provide a
reliable function or service (L. D. Miles)
“The ratio of Function to Cost”
Where,
Worth = Product, Delivery, Service, Fast Response,
Programs, Merchandising, Credit, Relationship, Accuracy,
Reliable Information, Problem Solving, Technical
Assistance, Sales Person/Rep, Cheerfulness, Sympathy
Cost = Price, Problems, Hassle, Time, Confusion,
Misunderstanding, Fear, Frustration, Unnecessary Repeat
Phone Calls, Processing Deductions, Returnable Product.
Function = The specific worth that a design/item
must perform
Quality = The owner’s or user’s needs, desires, and
expectations
Cost = The life cycle cost of the product/project.
Value = The most cost effective way to reliably
accomplish a function that will meet the user needs,
desires and expectations.

4. Why & When to Apply Value Engineering ?
Value Engineering is used to determine the best design
alternatives for Projects.
Value Engineering is used to reduce cost on existing
Projects.
Value Engineering is used to improve quality, increase
reliability and availability, and customer satisfaction.
Value Engineering is also used to improve
organizational performance.
Value Engineering is used to improve schedule
Value Engineering is used to reduce risk
Value Engineering is a powerful tool used to identify
problems and develop recommended solutions.
Fig Product Design Influence
THE VALUE METHODOLOGY
The VM Job Plan covers three major periods of
activity: Pre-Study, the Value Study, and Post-Study. All
phases and steps are performed sequentially. As a value
study progresses new data and information may cause the
study team to return to earlier phases or steps within a
phase on an iterative basis. Conversely, phases or steps
within phases are not skipped.
 PRE-STUDY
 VALUE STUDY
A. Information Phase
B. Function Analysis
Phase
C. Creative Phase
D. Evaluation Phase
E. Development phases
F. Presentation / Result /
conclusion Phase
 POST STUDY
Now I Have Applied All the Phases to the Same
Project Car door window regulator.
I. VALUE STUDY (INFORMATION PHASE)
In the literature, lots of patents about different types of
window regulators can be found. These window regulators
can be grouped into five main headings according to their
functioning. These are screw driven window regulators,
window regulators utilizing rack and pinion, window
regulators comprising lazy tong mechanisms, window
regulators using pulleys and window regulators using
arms.
Screw driven window regulators use power
screws to raise and lower windows. One the early patents
belongs to Kraemer in 1928. In this design, the window is
attached to the nut of the power screw. Power screw is
driven with a handle with actuating gears. In Figure, a
describing drawing of the patent is given.
Figure An early screw driven window regulator
mechanism
Another type of window regulator mechanisms
employs racks and pinions to provide translation for
windows. An early example belongs Bell and Schoenleber
patented in 1920 . In this patent, the power from the
handle is transmitted to rack to and pinion pair trough

5. gears and chains. With rack and pinion, the window is
raised and lowered
A different patent belongs to Rietdijk taken in 2008. In
this design, window is attached to the electric motor.
Window regulator is operated by an electric motor driving
rack and pinion with a gear set.
Another group of window regulator mechanisms
utilizes lazy tong mechanisms to obtain translational
motion of the window. An early example is patent of
Eckey taken in 1914. In this patent, a handle drives the
lazy tong mechanism with gears. Also, window is
connected to the tip of lazy tong mechanism, by this way
window is raised or lowered through the window frame. A
describing drawing of this patent is given in Figure
Figure A window regulator mechanism utilizing rack
and pinion
A further example is patent of Walters taken in 1989.
In this design, the window is connected to tip of the
lazy tong mechanism. The motion of the window is
obtained by a lazy tong mechanism which is driven by
an electric motor with a power screw.
A different group of window regulators employs
pulley and wires to obtain the translational motion of the
window. One of the early patents of this type belongs to
Cousinard in 1921. In this patent, window moves along the
window frame by pulleys and wires. In addition, pulleys
are powered by a manual handle. A drawing of this patent
is given in Fig.
Another example is a patent belonging to Kuki,
Isomura, Suzumura, Sakakibara and Ishihara taken in
1991. In this patent, window is attached to a bracket
moving on a guide rail which is fixed to car door. The
motion of this bracket on guide rail is supplied by a
pulley and wire mechanism connected to an electric
motor. A describing drawing of this patent is shown in
Figure.. In another patent belonging to Medebach, two
guide rails are used with brackets. Again, these brackets
are attached to window and move with a different pulley
and wire mechanism.
Fig Window regulator mechanism using pulleys and
wires
Fig. A different window regulator mechanism using
pulleys and wires
the arm is rotated with a gear set one of which attached
handle. In Figure, a describing drawing of this patent is
shown.
Last group of window regulators utilizes arms to
operate the mechanism. There are lots of patents about
different types of window regulators comprising arms. An
early example is a patent of Seegers & Sohn taken in 1922
[10].
II. FUNCTION ANALYSIS PHASE (CONCEPTUAL
DESIGN)
Introduction
In the conceptual design stage, different concepts
should be generated and then the best concept should be
selected to satisfy design needs. At the selection of best
concept, the evaluation of created concepts is performed
subjective by its nature. Therefore, conceptual design is
another critical stage of the study.
In this chapter, firstly the created concepts are
presented in concept development and presentation.
Afterwards, concept evaluation criteria are defined.
Lastly, the best concept is selected among created
concepts using concept evaluation criteria. The procedure
followed in this chapter is a simpler version of the
conceptual design .
Concept Development and Presentation
Literature survey constitutes the background for
concept development. Therefore, five different concepts
are created based on types of window regulator
mechanisms found in the literature survey.
Concept I
The first developed concept is the screw-driven
window regulator mechanism. In this concept, the motion
of the window is provided by a power-screw mechanism.
The screw is fixed to the car door. In addition; the nut is
attached to the power screw with a casing and driven by an
electric motor through a gear set. Electric motor and gear
set are secured in a casing. The rotation of nut is free in the
casing. Furthermore, the window is rigidly attached to the
casing of the nut and guided through the window frame.
Therefore, as the nut is driven by the motor, the window
makes a translational motion through the window frame.

6. An illustrative sketch of Concept I is given in Figure.
Nowadays, car doors are manufactured in a curved shape.
Thus, the window should make a curved motion in the
window frame. So, the screw is illustrated in a curved
manner.
Figure An illustrative sketch of Concept I
Concept II
Figure A descriptive sketch of Concept II
The second concept is operated by a rack and pinion. In
this concept, the rack is fixedly connected to the car door.
The pinion is attached to the rack in a casing to secure the
connection between them. Furthermore, the pinion is
driven by a gear set powered by an electric motor which is
also connected to the casing. In addition, the window is
also rigidly connected to the casing. Thus; as the pinion is
rotated, the window makes a translational motion along the
rack.
In Figure, a descriptive sketch of the Concept II is
given. Note that, the rack should be also in a curved
shaped in the side view to provide the aforementioned
curved motion of the window.
Concept III
Third concept is utilizing wire and pulleys. In this
concept, a wire is attached to the main pulley which is
rotated by an electric motor. This electric motor is
connected to the car door chassis. In addition, the wire is
also connected to a bracket moving on a carriage which is
fixed to the car door chassis. Furthermore, the window is
rigidly attached to the bracket. So, when the main pulley is
rotated, the bracket is pulled along the carriage with the
help of two additional pulleys.
An explanatory sketch of the Concept III is shown in
Figure Note that, the carriage should be also in a curved
shaped in the side view to provide the aforesaid curved
motion of the window.
Concept IV
Fourth concept comprises an arm type mechanism. In
this concept, an arm is rigidly connected to a gear which is
driven by a pinion. A slider is attached to the tip of the arm
and connected to a moving slide. The window which is
guided through the window frame is fixed to moving
slide. In addition to these, the pinion is operated by an
electric motor. Therefore; as the pinion is rotated by
the electric motor, the window makes a translational
motion through the window frame.
An illustrative sketch of Concept IV is given in Figure.
Note that, the arm can bend to provide the abovementioned
curved motion of the window.
Figure An explanatory sketch of Concept III
Figure An illustrative sketch of Concept IV
Concept V
The last concept utilizes a cross armed or a scissor
mechanism. The input link of the cross armed mechanism
is fixed to a gear which is driven by a pinion. The window
is rigidly attached to the moving guide of the cross armed
mechanism and guided in the window frame. In addition,
the pinion is driven using an electric motor. Therefore, as
the input link is operated, the window makes a
translational motion through the window frame.
In Figure, a descriptive sketch of the Concept II is
given. Note that; as in Concept IV, arms can bend to
provide the curved motion of the window.

7. Figure 2.5 A descriptive sketch of Concept V
Concept Evaluation Criteria
After concept development is completed, the next step
is clarifying concept evolution criteria. Concept
evaluation criteria can be chosen among a variety of
technical, economic, technical, etc. aspects. However,
these criteria must be selected such that differences
between concepts can be observed during the evaluation
process.
Chosen evaluation criteria are small number of
components, low complexity of components, low
complexity of concept, long service life, regular force
transmission, low noise operation, simple assembly and
low space utilization.
Small number of components is mainly a cost criterion
since number of components directly affects the overall
cost of the product. If the product consists of higher
number of components, more materials will be used in the
manufacturing stage of the product.
Low complexity of components also affects cost of the
product. Because, complex components necessitate using
different production techniques resulting in a costly
manufacturing stage. In addition, operational problems
may occur because of complex components.
Low complexity of concept influences functioning and
design process of the product. Because, complex designs
demand complex sub-functions and assemblies which
may cause a worse functioning of the design. Long service
life directly affects maintenance cost of the product.
Furthermore, regular force transmission influences
functioning and maintenance of the product. Because,
undesired force transmission may cause higher reaction
forces resulting high wear of components.
Lastly, simple assembly and low space utilization
influences assembly stage of the product.
Table 1 Value scale used for the evaluation of concepts
Point
s
Meaning
0 Absolutely useless solution
1 Very inadequate solution
2 Weak solution
3 Tolerable solution
4 Adequate solution
5 Satisfactory solution
6 Good solution with few drawbacks
7 Good solution
8 Very good solution
9 Solution exceeding the requirement
10 Ideal solution
Table 2 Assigned weights to concept evaluation criteria
Evaluation Criterion
Concept 1 Concept 2 Concept 3 Concept 4 Concept 5
Small Number of Components 4 5 6 5 6
Low Complexity of Components 6 5 6 4 5
Low Complexity of Concept 7 6 7 5 3
Long Service Life 4 5 7 6 5
Regular Force Transmission 3 4 8 5 4
Low Noise Operation 3 4 9 6 5
Simple Assembly 6 3 8 5 4
Low Space Utilization 5 4 8 4 3
Total Points 38 36 59 40 35

8. After Analyzing if above Table concept 3 is the best
alternative Among all concept so, I have chosen it for
further Improvement.
In these window regulator the regulator carriage plate
has a scope to further improvements so from onwards in
these project specially focused on regulator carriage plate
only.
III. CREATIVE PHASE
A. MECHANICAL MODELING
CATIA V5 is mechanical design software, addressing
advanced process centric design requirements of the
mechanical industry. With its feature based design
solutions, CATIA proved to be highly productive for
mechanical assemblies and drawing generation. CATIA,
with its broad range if integrated solutions for all
manufacturing organization. CATIA is the best solution
capable of addressing the complete product development
process, from product concept specification through
product service in a fully integrated and associative
manner. CATIA mechanical design solutions provide tools
to help you implement a sophisticated standard based
architecture.
Fig Part Windows carriage Plate
B. DRAFTING
Drawings and documentation are the true
products of design because they guide the manufacture of
a mechanical device. CATIA automatically generate
associative drafting from 3D mechanical designers and
assemblies. Associability of the drawings to the 3D master
representation enables to work concurrently on designs
and drawings. CATIA enriches Generative Drafting with
both integrated 2D interactive functionality and a
productive environment for drawings dress-up and
annotation.

9. IV. EVALUATION PHASE
MESH GENERATION:
In the finite element analysis the basic concept is to
analyze the structure, which is an assemblage of discrete
pieces called elements, which are connected, together at a
finite number of points called Nodes. Loading boundary
conditions are then applied to these elements and nodes. A
network of these elements is known as Mesh. Symmetry
Conditions
FINITE ELEMENT GENERATION:
The maximum amount of time in a finite element
analysis is spent on generating elements and nodal data.
Pre processor allows the user to generate nodes and
elements automatically at the same time allowing control
over size and number of elements. There are various types
of elements that can be mapped or generated on various
geometric entities.
The elements developed by various automatic element
generation capabilities of pre processor can be checked
element characteristics that may need to be verified before
the finite element analysis for connectivity, distortion-
index etc. Generally, automatic mesh generating
capabilities of pre processor are used rather than defining
the nodes individually. If required nodes can be defined
easily by defining the allocations or by translating the
existing nodes. Also on one can plot, delete, or search
nodes. The finite element method is numerical analysis
technique for obtaining approximate solutions to a wide
variety of engineering problems. Because of its diversity
and flexibility as an analysis tool, it is receiving much
attention in almost every industry It is not possible to
obtain analytical mathematical solutions for many
engineering problems. An analytical solutions is a
mathematical expression that gives the values of the
desired unknown quantity at any location in the body, as
consequence it is valid for infinite number of location in
the body. For problems involving complex material
properties and boundary conditions, the engineer resorts
to numerical methods that provide approximate, but
acceptable solutions.
The finite element method has become a
powerful tool for the numerical solutions of a wide range
of engineering problems. It has been developed
simultaneously with the increasing use of the high- speed
electronic digital computers and with the growing
emphasis on numerical methods for engineering analysis.
This method started as a generalization of the structural
idea to some problems of elastic continuum problem,
started in terms of different equations..
If the physical system under consideration
exhibits symmetry in geometry, material properties, and
loading, then it is computationally advantageous to model
only a representative portion. If the symmetry
observations are to be included in the model generation,
the physical system must exhibit symmetry in all of the
following:
Geometry, Material properties, Loading, Degree of
freedom constraints.
A three-dimensional finite element mesh of the structure
contains tetrahedral elements with nodes.
MESH
BOUNDARY CONDITIONS
Material 1 ( Steel )
Analysis
1.0 Force Applied on Force 100N
Fig Force Applied on Force 100N
2.0 Force Applied 100N Carrier Plate With
Meshing
Entity Size
Nodes 2953
Elements 8270
Material Steel
Young's modulus 2e+011N_m2
Poisson's ratio 0.266
Density 7860kg_m3
Coefficient of thermal
expansion
1.17e-005_Kdeg
Yield strength 2.5e+008N_m2

10. Fig Force Applied 100N Carrier Plate With
Meshing
3.0 Stress on plate 100N, Result --
(2.42x10^7Pa)
Fig Stress on plate 100N, (2.42x10^7Pa)
4.0 Translational displacement 100N, Result--
(0.000887mm)
Fig Translational displacement 100N,
(0.000887mm)
5.0 Stresses And Translational Displacement
Fig stresses and translational displacement
V. IMPROVEMENT / DEVELOPMENT PHASE
At the beginning of the design process, it was
necessary knowing the problem of current design to
understand the requirements that required. The literature
study was one of the main problems from the beginning of
this thesis. To find related information was quite difficult.
The work in the Section study of a standard car door
window regulator was very useful in this project for
understanding the performance, materials and components
of a car door. As well as the function analysis was very
helpful to establish the initial project specifications.
The project had to be done in the software CATIA. It
took some time that would have been spent on the
implementation of the report. As the project progressed,
the solution space seemed to be more limited. Perhaps the
biggest contribution of the work was in choosing and
proposing ideas within the window and its mechanisms.
Several methods were used for the development of the
concept generation: benchmarking, and concept
classification tree using decomposing by user needs. After
these methods several concepts were selected among some
ideas thanks to the Concept combination table. Perhaps,
more ideas could have been generated applying different
and more methods, but the lack of time due to first stages
of the project caused a more direct search of concepts. The
final stage of the design process is the realization of the
final design concept. This is not strictly in this thesis due to
the final choices will be taken into the companies own
design process before the manufacturing because of factors
outside the control of this project.
The product development and preliminary application
of VE/VA technique is a powerful tool for product cost
optimization which attacks on product design,
procurement, production inventory, product assembly
process, product manufacturing stages, etc. Prior
involvement of VAVE techniques during concept and
design stage of new product phases reduces the overall
lifecycle time and reduces product cost, wastage (lean),
increase product reliability, high customer satisfaction, etc.
resulting in better and optimal techniques and
methodologies for product cost optimization. A case study
has been conducted to optimize the cost of a sub- assembly
of automotive component. The cumulative effect on the
cost saving for the large lots will result into considerable
amount of saving. It not only saves or optimized the
product cost but also plays a great role in the overall
organization profit margin. Consequently, the
implementation of VE/VA techniques is planned into the
major areas of automotive Product design and
development across the organization.
The project suggests the material selection in
combination with structural optimization procedure.
Employing the well-developed techniques we organized
them in one system that allows solving the problem of
material selection based on structural optimization
including mechanical analysis of a component. In other
words, the optimal material choice according to the
constructed system is based on the best potential of each
material-candidate in mechanical behavior under given
load and boundary conditions. Other parameters such as
recyclability, manufacturability, etc., can be also included
into consideration, if available.
Detailed strength analyses are not carried out
during the detailed design stage because forces acting
on the links of the mechanism are relatively small. But, to
improve the design, detailed strength analyses can
be performed. Optimization study for detailed strength
analyses can be made considering weights of the linkages
of the window regulator mechanism. In this manner,
overall weight of the mechanism can be reduced. Analysis
of the internal logistics of the company under
consideration has shown large potential of production

11. optimization in respect of material flow and, consequently,
minimization of the costs involved in it.
By removing unnecessary material with control on
following parameters
1. Reduce the weight as more as possible.
2. No reduce in strength of a part.
3. Maintain a stress of part in a permissible limit.
4. If Possible replace a metal material by Thermoset
Plastic material.
5. Find out a more functional design which has no
maintenance & corrosion free.
Remove extra material- To reduce the weight of plate
without hampering strength and center of gravity of plate,
6 holes are created which are along the circumference of
the point of center of gravity.
Material and Structure Optimization
Fig. Modified Carrier Plate ( 6 Holes )
Material 2 ( Plastic)
Material Plastic Polyamides
Young's modulus 3.2e+009N_m2
Poisson's ratio 0.36
Density 1120 kg_m3
Coefficient of thermal expansion 1.49e-4 strain/°C
VI. CONCLUSION / RESULT
In the Case Study discussed above we see how the cost
of a product is minimized by applying the Value
Engineering Methodology. Value Engineering is the
systematic application of recognized techniques by a
multi-disciplined team which identifies the function of a
product or services; establishes a worth for that
function; generates alternatives through the use of
creative thinking; and provides the needed functions to
accomplish the original intent of the project, reliably and at
the lowest life-cycle without sacrificing project
requirements for safety, quality, operations,
maintenance and environment. Various worksheets are
developed and thorough analysis is done to attain a
concrete solution. With the use of VAVE technique, the
product cost has been optimized with around 6% reduction
Comparison of the results of the materials selection
according to different approaches (via the material indices
and the compound objective function) showed that the
optimal material choice depends on the formulation of the
problem as well as on the applied criteria and method. In
addition, the possibility to use Plastic in automobile
structures was examined in comparison with the
conventional (steel, aluminum alloy) and non-conventional
(metallic and synthetic fiber composites) materials based
on the given case study.
 By making hole in carriage plate weight
reduction is up to 6%
 The study helped in designing plastic door
window regulator module plate for car body
application using Plastic Polyamides material,
topology and shape optimization techniques.
 Final design of the plastic door module is
40% lesser in weight with improved
structural, properties compared to existing
steel door module plate.
 The design and analysis methodology adopted
here to design plastic door module plate to
replace existing steel door module plate can
be adopted to design and analysis plastic parts
to replace semi structural automotive parts
currently made from steel.
VII. REFERENCES
[1] Automotriz. (2015). Partes de la puerta de un coche
[ONLINE] Available at:
<http://www.automotriz.biz/coches/cars-trucks-
autos/other-autos/112630.html> [Accessed 9 April
2015].
[2] Cabello, J., Márquez, F., Pérez J.M., & Verdier, C.
(2009). Industrial Design Methodology / Metodología
del diseño industrial. 1st ed. Málaga: SPICUM
servicio de publicaciones.
[3] Cross, N. (2008). Engineering design methods:
strategies for product design. 3rd ed. Chichester:
Wiley.
[4] EHow En Español. (2015). Partes de la puerta de un
coche [ONLINE] Available at:
Weight before holes Weight after holes Percentile reduction in weight
200gm 188gm 6%

12. [5] <http://www.ehowenespanol.com/partes-puerta-
coche-lista_319708/> [Accessed 12April 2015].
[6] Krolczyk, G.; Legutko, S.; Krolczyk, J.; Tama, E.
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[7] Starbek, M.; Menart, D. The optimization of material
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[8] Venkateswaran, J., and Son, Y., 2005, Production
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[9] Access to success: Value Engineering, Mani Mala,
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[10] Kraemer, W. L., Window Opener, Patent No:
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[11] Szkozinski, A., Direct Drive Vehicle Window
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[12] Dod 4245.8-H Value Engineering March 1986 [6]
Val u e E n g i n e e r i n g w h i t e p a p e r ,
www.kpitcummins.com
[13] http://www.value-engineering.com/consulting.htm
[14] http://www.wordiq.com/definition/Value_engineering
[15] http://en.wikipedia.org/wiki/Value_engineering
[16] http://www.nab.usace.army.mil/whatwedo/ValueEngi
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