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IRJET- Value Analysis for Cost Saving in Mechanical Pencil Manufacturing: A Case Study
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1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 8225 Value Analysis for Cost Saving in Mechanical Pencil Manufacturing: A Case Study Shankar Sahu1, Hariom Maurya2, Ankit Maurya3, Anupam Mishra4, Shital Patel5 1,2,3,4B.E. Student, Department of Mechanical Engineering, Bharati Vidyapeeth College of Engineering, Kharghar, Navi Mumbai. India 5Professor, Department of Mechanical Engineering, Bharati Vidyapeeth College of Engineering, Kharghar, Navi Mumbai. India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - The objective of this study was to analyze the prospect of cost reduction through value analysis technique. A manufacturing process of a conventional leadpencilisstudied to apply the value analysis technique in order to decrease the cost. Value analysis is the study of the current processes to reduce the cost incurred on the manufacturing of a product through process reengineering ordesignmodification without reducing the performance of the product regarding its elementary functions. This study focuses on the design amendment of the mechanical pencil by varying materials used for manufacturing of the pencil. This study presents the purposeful cost analysis of lead pencil and ideas are projected to reduce the cost of manufacturing per product. Through newly projected ideas, cost saving per pencil is foreseeable to be 25% of the former manufacturing cost. Key Words: Value Analysis, Cost reduction, Pencils, Cost Minimize, Function Analysis. 1.INTRODUCTION Value Engineering establishes an association between value and price of a product by evaluating its functions to determine the best value. When a product accomplishes its essential functions reliably at the lowest life-cyclecostwhile preserving the quality labelled as the best value of that product. Value engineering is the set of activities performed while the product is in the design & progress phase. On the contrary, value analysis is a technique implemented for the cost reduction and procedure development for the current product. Value of a product is well-definedbytheproportion of the functions performed by the product to the cost of that product. It has been proved that Value analysis can reduce costs by 25% to 45% or even more without disturbing its quality. The manufacturing process of mechanical pencil roughly comprises cutting and shaping of wood, inserting lead into the wood, coating of wood, and lastly, assembly of the metal lid along with the eraser. A study was directed to gather the information about present estimate of the pencil to discover the extents where enhancement is likely, along with the functional examination of the numerous parts and procedures to studytheir importanceintheprocedure.In the technical terminology of the value engineering, this phase is known as the orientation phase. In order to cut the cost incurred on the production of the mechanical pencil, the comprehensive study of present figure is undertaken to recognize the possible areas of enhancement. The overall study presented that the minor design aspects can produce a substantial impact on the cost of manufacturing and need to be prudently studied. The concepts presented in this manuscript suggest a minor variation in the design of the product by changing the shape and coating used during manufacturing of the pencil. The potential of the concept is also explored in this text through the probable reduction in the costofmanufacturing.Further, the current and newly projected costs are compared to estimate the cost saving per piece. The process of cost reduction through value analysis is described through this manuscript. 2. VALUE ANALYSIS & VALUE ENGINEERING According to the Society of American Value Engineering, “Value engineering is the systematic application of familiar techniques which recognize the function of a product or services, establish a financial value for the function and deliver the necessary function reliably at the lowest overall cost.” The objective of value analysis is not only to degrade or low- price the products but to advance its value by reducing cost. Value analysis is applied to the current product in order to enhance its value. Whereas, Value Engineering is applied to the product at the design phase and therefore ensures prevention rather than elimination. The value analysis must be applied at the appropriate period and exact stage of product life cycle to get expected results. 3. VALUE ANALYSIS: PHASES i. Orientation Phase In this phase, functional analysis of numerous parts and processes is carried out to separate them into basic and subordinate functions. The separation is done based on the discrete function and their functional input toassembly.The elementary function is what a product or process must do to work or sell, and the buyer is ready to pay for, trailed by subordinate functions that support that basic function. Subordinate functions can be revised or removed to
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 8226 condense product cost. The pencil is mainly divided into the following components: - 1. Lead 2. Wood 3. Metal cap 4. Eraser 5. Coating The functional analysis is also presented in Table. 1, based on their influence on the assembly. Sr No. PART NAME FUNCTIONAL DEFINITION VERB NOUN 1 LEAD MAKE INDENT 2 WOOD PROVIDE STRENGTH 3 METAL LID PROVIDE PROTECTION 4 WOODSHAPE PROVIDE GRIP 5 PRINTING DISPLAY INFORMATION 6 COATING IMPROVE AESTHETIC 7 ERASER CLEAR MARKS Table. 1: Functional Analysis of Parts and Processes ii.Knowledge Phase In the knowledge phase, the detailed information regarding the costing of the pencil is gathered from the survey of the production line. The pencil manufacturingconsistsofoverall 5 stages. As a unit, the current manufacturing cost of the pencil per piece is ₹ 5/-. Wood and coat are the two expensive elements in the manufacturing of a pencil which share 37.5% of the total cost of a pencil. The primaryfocus is kept on these two elements for the cost reduction. The detailed costing of the parts and processes is presented in the following table. SR. NO. PART NAME QUANTITY COST IN Rs. 1 LEAD 1 1 2 WOOD 1 1.5 3 METAL LID 1 0.25 4 SHAPING OF WOOD 1 0.50 5 PRINTING 1 0.8 6 COATING 1 0.15 7 ERASER 1 0.8 TOTAL 5.00 Table. 2: Detailed Estimate of Parts and Processes Chart-1: Components & Cost Distribution Key Letter Part Function Weight % Cost A LEAD MAKE MARK 8 20 B WOOD PROVIDE STRENGTH 8 10 C METAL LID BASE PROTECTION 7 5 D SHAPING OF WOOD PROVIDE GRIP 3 10 E PRINTING DISPLAY INFORMAT ION 2 16 F COATING IMPROVE APPEARANCE 1 12.5 G ERASER REMOVE MARKS 4 16 Table. 3 Comparison of Functional Weight and Cost Chart 2: Functional weightage & cost
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 8227 iii. Creative Phase This phase is concerned with, “Whatarethe alternate possibilities which could satisfy the same functions” of the assembly. Many concepts are generated and discussed in the brainstorming conference. Following thoughts were made during this phase. 1. Change in the design (round shape) Instead of using the hexagonally shaped woodforthe body of pencil, the triangular shaped design can be incorporated to reduce the manufacturing time and thereby, manufacturing cost. 2. Eliminate polished coating (use matte coating) Polished paints are expensive and great care is to be taken whileapplying ison the wood. Instead of that, the matte paints can be used to save the cost & improve aesthetics. 3. Use plastic lid instead of metal lid. Manufacturing of metal lid is expensive as compared to plastic lid. Plastic Lids are light in weight.Hence it would require less effort to write. After discussing the concepts put forth, the function cost worth analysis is performed on the product to estimate the effectiveness of the newly proposed ideas. Table. 4: Function Cost Worth Analysis iv. Assessment Phase This phase is concerned with the alternate possibilities which could satisfy the same functions of the assembly. Many concepts are generated and discussed in the brainstorming conference. Following thoughts were made during this phase. In the evaluation phase, the costing of the new ideas is done considering the monthly demand of 5000 pieces. The percentage saving and total per order are also calculated. Saving per product = ₹ 0.55/- % saving per product = 11 % Monthly demand = 8000 The actual monthly overall cost = ₹ 40000 /- The new monthly overall cost = ₹ 35,600/- Total monthly saving = ₹ 4,400/- Chart 3: Current & Estimated costs 4. CONCLUSION With the projected design changes, it is likely to cut the cost for the manufacturing of one unit of the pencil by 11%. It isa massive reduction in cost. The savings expected per order is ₹ 4400 /- which can be used for the further manufacturing of nearly 880 extra pencils. Along with the straight financial advantage, the manufacturing process would be made simpler which will result in thelesser productiontime.Itwill be possible to manufacture more products with the same given time for a lot. The new design will also give the product a more aesthetic look which will be more appealing to the customers. New concepts are alsolikelytoattainmore buyer fulfilment along with performance enhancement and cost saving. PART CURRENT COST in Rs. NEW COST in Rs. IMPROVEMENTS LEAD 1 1 No Change WOOD 1.5 1.5 No Change LID 0.25 0.1 Plastic Lid WOOD SHAPE 0.5 0.1 Triangular Shape PRINTING 0.8 0.8 No Change COATING 0.15 0.15 Matte Coating ERASER 0.8 0.8 No Change TOTAL 5 4.45 No Change
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International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 8228 REFERENCES [1] Analysis, F. (2012). Improving Furniture Product through Value Engineering by Function Analysis Systems Technique (F. A. S. T.), 1(4), 5–11. [2] Rohilla, K. (2017). Implementation of ValueAnalysisin an Indian Industry: A Case Study, 12(1), 33–48. [3] Gardas, B. B., Shimpi, N. R., & Mahajan, S. B. (2013). Value Analysis for a Mumbai Local Train: A Case Study, 3(6), 1–3. [4] Sevillian folding chair. (n.d.), 1–6.
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