Application of Value Engineering in Enhancing Value of Automobile Tail Light Assembly

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Description of Proposed Work

OBJECTIVE

The objective of this V.E study is aimed at enhancing the value of tail light assembly by modifying and simplifying the design, decreasing the number of parts used in assembling the tail light as it currently stands, yet performing the same function without any compromise.

Also the process of stamping, pressing sheet metal, cables, bulbs, holders and quality assurance and cost incurred in maintaining tolerance between mating parts are reduced.

METHODOLOGY

V. E. Methodology as outlined in Thomas R. King’s book: “Value Engineering: Theory & Practice in Industry” has been incorporated during this project. The Value Engineering Methodology Job Plan, and how each phase was applied to the proposed project are mentioned below.

MODEL STRUCTURE

Table 1.0

5 Phase Job Plan

Improve Tail light assembly

Information

Taillight cost service research on two comparable models

Analysis

Cost comparison charts

Creativity

Other parts that can be used in place of this? (Reflectors)

Evaluate

Prioritize/rank/combine ideas

Implementation

Execute developed plans

Value Engineering Tools and Techniques used in our project

Steps of the VE Job Plan

Tools & Techniques

Information

- Data collection

- Benchmarking

Function

- Function Analysis

- F.A.S.T. Diagram

Creative

- Brainstorming

Evaluation

- Numerical Evaluation

- T-Chart

Implementation

- Graphs

- Tables

Value Methodology Job Plan

- Information Phase:

Technical details were gathered regarding the Tail Light Assembly. The primary purpose of this phase was for a deeper understanding of the project and for determination of the cost of having split tail light assembly.

There are various models of different automobile companies with tail light assembly provided on the chassis as well as on the trunk deck. On average this leads to additional wiring harness, bulbs, holders, colored light covers. It also leads to increased cost of the cutting the metal, quality issues etc.

Cost estimate for the current design

Current Tail Light assembly model typically include:

8 bulbs ( 10 watts)

$ 3.00 per piece

8 bulb holders

$ 2.00 per piece

4 light covers

$ 15.00 per piece

5-6 yards cable

$ 1.5 per yard

Gasket

$10 per unit

Hex nuts

$ 1 per unit

Connectors, etc.

$ 2.00 per assembly

Miscellaneous parts

$ 5 per unit

These values are figures from a auto-store and may or may not reflect the actual cost that the auto manufactures incurs as that information is confidential. We believe this data is accurate for the scope of this project.

- Function Analysis Phase

The primary purpose of this phase was to define the basic function of the various parts being used in the tail light assembly. After much analysis, the basic function was determined to be “Lower Part Complexity”. During this VE phase, tools utilized were: FAST diagramming, Function analysis.

Function Worksheet

Component

Function Description

Verb-Noun

Basic

Secondary

Bulb

Generate light

Improve appearance

Holder

Hold components

Permit Removal

Wire

Conduct current

Bend Direction

Colored covers

Impart Color

Reflect light

Laser Cutting

Create Cavity

Remove Metal

Gasket

Seal Surfaces

Prevent leaks

Hex nuts

Secure assembly

Hold components

Functional Analysis System Technique Diagram