Value engineering

A Management Perspective,[object Object],Value EngineeringA Case Study of the Indian Railways,[object Object],Dr. Chandan Vichoray,[object Object],BE, MBA, Ph.D,[object Object]

Introduction,[object Object],A Systematic Method to improve the value of goods or products and services by using an examination of a function,[object Object],Value is the ratio of function to cost,[object Object],Value can be improved by:,[object Object],Improving the function,[object Object],Reducing the cost,[object Object]

Types of Values,[object Object],There are Four Values:,[object Object],Use Value,[object Object],Cost & Exchange Value,[object Object],Esteem Value,[object Object],Scrap Value,[object Object]

The General Value Engineering Job Plan,[object Object],Following steps are generally followed:,[object Object],Information Gathering,[object Object],Alternative Generation,[object Object],Evaluation,[object Object],Presentation,[object Object]

The Indian Railways Case Study,[object Object],The Value Engineering Project was carried out at the Central Railway Electric Locoshed (ELS) Ajni.,[object Object],Problem identification was done based on resource utilization focussed on Use Value and Cost Value,[object Object],The Process involved redesigning of the Journal Bearing Lubrication Pump mounted on the Axle Shaft,[object Object]

Problem Definition,[object Object],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,[object Object],The Pinion actually drives an Oil pump gear assembly which is submerged in a sump of Oil,[object Object],This assembly provides for a thin film lubrication to the Journal Bearings mounted on the Axle Shaft of the Locomotive,[object Object],This lubrication keeps the friction away and also cools the wheel parts while the train runs,[object Object],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,[object Object]

Digramatically,[object Object]

The rise of the problem,[object Object],Breakage of the Gear in Two Halves (GITH) mounted on the Axle Shaft due to Impact Loading,[object Object],Changing GITH involved:,[object Object],Dismantling the body,[object Object],Removing the Central Transformer,[object Object],Removing the Traction motor of the affected Axle Shaft,[object Object],Changing the GITH,[object Object],Again Assembling the aforementioned parts,[object Object]

The Management Angle,[object Object],Involved 8 people plus a dedicated Gantry for lifting the Central Transformer, Traction Motors and other parts,[object Object],Required a total of 192 Man hours to change a small part,[object Object],Occupied Pit line for only this work for 24 hours,[object Object],Increased downtime of the Locomotive,[object Object]

Alternatives,[object Object],Initially a study of the design of the system was carried out,[object Object],It was found out that multiple procedures resulted in the fault,[object Object]

Alternatives,[object Object],Initially a study of the design of the system was carried out,[object Object],It was found out that multiple procedures resulted in the fault,[object Object],Based on the kind of problems the various solution alternatives were found out,[object Object]

The Identified Problems,[object Object],The Basis of design was changed,[object Object],Weight of the Pinion,[object Object],The Oil Pump Gear Shaft,[object Object],Non-Standard Specifications,[object Object]

Design Basis Problem,[object Object],The Basis of design was changed,[object Object],The Pinion in this case is the driven gear,[object Object],The Hardness of the GITH was less than that of the Pinion,[object Object],The GITH was the hardest to change,[object Object]

Design Basis Problem Solution,[object Object],The Basis of design was changed,[object Object],The GITH was the driving gear hence the design process was based on GITH,[object Object],The Hardness of the GITH was made more than that of the Pinion,[object Object]

Pinion Weight,[object Object],The Weight of the Pinion was one of the big hindrance,[object Object],Face width of the Pinion was broader contributing to the weight gain,[object Object],Broader face width was foreseen as a solution to proper meshing on turning tracks,[object Object],The weight acted on the Gear shaft of the oil pump gear,[object Object]

Pinion Weight Solution,[object Object],Weight of the Pinion was reduced by reducing the face width based on historical data,[object Object],Suggested on the use of Teflon material for manufacturing the Pinion to further reduce the weight,[object Object]

Oil Pump Gear Shaft,[object Object],Oil Pump Gear Shaft was tapped for screwing the shaft on to the pinion on the taper side,[object Object],The material clearance between the internal threading and key way was very less,[object Object],The less clearance was responsible for the breakage of the Oil pump shaft leading to impact loading on the GITH due to Pinion,[object Object]

Oil Pump Gear Shaft Solution,[object Object],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,[object Object],Securing the OPGS with a castle nut so as to ensure zero play during meshing,[object Object]

Non-Standard Specification,[object Object],All specifications are non standard considering the manufacturing done by GEC Alsthom.,[object Object],Parts with such specifications are difficult to manufacture in local units,[object Object],Leads to productivity delays as sourcing has to be done from the OEM,[object Object],Costlier Proposition,[object Object]

Value engineering

Value engineering

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Value engineering