A Monograph on Cost Optimization in Automotive Manufacturing: A Value Engineering and Functional Analysis Approach

In Chapter 1, we describe our problem and deliver the aim and objective of the project. Also give a justification why we must choose this problem.  The main aim of this project is to reduce the chain case cost by 21% in two - wheeler products using value analysis, value engineering and functional analysis. We will provide our month wise plan of work to achieve the target in this chapter.

In Chapter 2, we will elaborate the details of the organization TVS Group. The products of the TVS group, process, facilities which are available in the organization will be discussed in this chapter.  We will provide the organization structure, its business profile, achievements, awards and the milestone of this organization will be brief out in this chapter.

In Chapter 3, we will state the problem and discuss in detail the importance of the problem. It is necessary to retain the contribution of the product without increasing the selling product to sustain the market share. We need to reduce the cost of a chain case to retain the vehicle contribution is our problem. Also, we will describe the reputation of a chain case before making the cost reduction approach. So we will clearly explain the scope, historical perspective, cause and effect and criticality of the problem in this chapter.

 In Chapter 4, we are going to discuss a few topics which are most relevant to this project. Also, we have surveyed the results from various research articles and case studies in the precise topic. Literature on automotive industry and need for cost reduction, value analysis and value engineering, functional analysis, metal to plastic conversion and Qc techniques.

In Chapter 5, the vast amount of data will be gathering which are related to our project.  Data gathering will be useful for two main purposes of process improvement and cost-effective solution. Finally, it will guide us to find the best cost-effective solution for process optimization, material selection across a different area of application.     

In Chapter 6, we will discuss the choice of techniques which is required for our problem discussion. We will discuss the function analysis with VE, function tree, function cost and finite element analysis. We will provide an analysis of plastic and metal. Also, we elaborate the scope of our in this project.

In Chapter 7, we will give a justification that plastic will be the better one than metal. Again, we will choose the type of plastic that will suit for the chain case more and will help to reduce the manufacturing cost of chain case.  Design of chain case is very important, so we will be attempted to redesign the already existed chain case.  For improvising the design, we redesign the internal design clearance, and we provide a procedure to overcome the chain cover rubbing also. Not only these changes, also we will improve the moulding design, gating design, cooling system and cooling fixture.  We explain in detail about the process, packing improvement and validate the concept and selection.

In Chapter 8, we discuss the overall results of this project in a different scenario. Validate the test result in the initial stage and try to find the fault in the process. After identifying the fault, we adopt the necessary actions and rectify the problem. At the end of the stage, we implement the changes in the vehicle and test the output. If everything is working properly, then we will get approval and validate the status of the product. The expected time, cost, effort, and overall expected benefits are described to validate the result.  Mainly it focuses on the achievement from this project and methodology adopted during its implementation.

In Chapter 9, we will summarise the project, discuss the limitation and gains of our study. Also deliberate the scope of future wok in this chapter.