VALUE ANALYSIS AND VALUE ENGINEERING

MANU 4351

SEMESTER 1, 2019/2020 SESSION

PROF. ERRY YULIAN TRIBLAS ADESTA

Done By:

GROUP 3
OMAR AHMAD ABDULHADI - 1521387
FAISAL SOFIAN ABUDAIA - 1428453
NAIF HOSSAM HAMED - 1426123
MUHAMMAD SOLLEHEN BIN MISNAN - 1522675
MUHAMMAD AZMERULL BIN MOHD AZMI - 1524159

Department of Manufacturing and Materials Engineering, Kulliyyah of Engineering,

International Islamic University Malaysia, 53100 Jalan Gombak, Selangor Darul Ehsan

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TABLE OF CONTENT

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LIST OF FIGURES

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 LIST OF TABLES

1. INTRODUCTION

Value analysis is a method concerned with the existing products. It is a method that

involves the product analyzation and evaluation by a team, to reduce costs, improve product

function or both. It is a step-by-step analytical approach to achieve the desirable result. In this case

study, a bidet is used as the object for evaluating the student ability to do the value analysis method

to increase the product value.

Bidet sprayer is a hand-triggered nozzle tools commonly installed in the toilet for body

cleansing purpose. It is a hand-tool used to spray out water when cleaning any body parts. This

tool is more common in the country where cleaning is more water-based rather than using other

cleaning method.

Problem Statement

Bidet, one of the first thing people commonly see when entering the toilet. In fact, it is one

of the must-have tools installed in the toilet. Because of the commonness of this product, we can

find many different designed bidets sold in the market which some of it does not really meet up

the standard and some of it have a luxury design which then hike up the price of it. Beside that,

we can also see a bidet design which seems not too comfortable for a use. Below are a few faulty

in the design which we found is not necessary to be implemented on the bidet:

1) Metallic body

This material has its own advantage such as the durability of the final products and the

classy look it brings to the bidet but it come with additional unnecessary cost for production

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 which then increase the selling price of the products. Additionally, metal is good heat

conductor. This property can make the bidet hard to hold as it gets really hot during the

summer as the water flow is hot because of the weather.

2) Too many parts

Having many parts sometime can be a good way of designing. Some products need to have

many individual parts for assembly because of the maintaining cost and some need it

because of the purpose it is designed for (i.e. portable products). However, having too many

assembled part for bidet is no necessary since it can increase the manufacturing cost. The

cost increment of the bidet happens because of the need to custom designed every parts

and components of the body to make it possible for assembly. So, reducing the parts can

be a good way to reduce the cost. But the question is, which part to reduce and which part

can be removed?

3) Unsafe outer design

The outer looks of products play a big role in the market. But not all of it are actually safe

to use. For example, having sharp edges may brings a nice look to the bidet but it can bring

harms to the user especially when it is designed using a hard material such as metal. In this

case, the designer must take into consideration that a kid might be inappropriately using

their products which can lead to injury.

Objectives

1. To enhance the functionality of the current bidet design.

2. To reduce the cost of the bidet.

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 2. LITERATURE REVIEW

3. METHODOLOGY

Orientation Phase

In the orientation phase, we first list down the problems which is manageable; - what can

be change, what can be reduced, what can be replaced and etc. This orientation phase is important

for the big products with a large number of components such as car, milling machine and etc. It is

inadvisable to do the value analysis and value engineering to whole car/milling machine. However,

bidet sprayer is small in size and has small numbers of parts, so applying value analysis to the

body is still manageable. As mentioned in the problem statement above, we choose three design

components from the bidet (material, number of parts and outer design) for implementing the value

analysis to improve the overall value of the bidet.

Information Phase

The original design of the bidet consists of 11 parts which we deem are too many for a

simple cheap tool made for daily use. Before brainstorming the idea of improvements, we first

analyze the outer looks of the bidet; - the dimension, mechanism, material, parts, and etc. After

that, we specify our market target so that our modifications are not going astray from the objective

why we improve the object (bidet). Lastly, we come out with the budget scope of the bidet; - how

much can be spent on individual part and what material to be considered so that the durability of

the final product is reasonable to the standard and the market.

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Functional Analysis

Bill of Materials

Functions Description

Part Part Description Function

1 Channel water basic

2 Connect Part 1 & 3 Secondary

3 Connect hose to bidet Secondary

3 Allow handheld of bidet Secondary

4 Close valve Secondary

5 Hold part 4 & 10 Secondary

6 Prevent water leakage Secondary

7 Prevent slipping Secondary

7 Allow rotation of part 7 Secondary

7 Prevent spoilage of part 8 Secondary

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 8 Avoid water leakage Secondary

9 Transmit pushing force Basic

10 Control valve Basic

11 Sprinkle water Secondary

11 Increase pressure Secondary

11 Provide comfort Secondary

FAST Diagram

Cost Function Matrix

Worth Function Estimation

Creative Brainstorming Stage

Early stage

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 Firstly, on this stage, the first proposed improvements on the current bidet sprayer design

were as follow:

1. Change the mechanism of water flowing

As shown below in Figure, the first proposed mechanism was by replacing the handle of

the bidet sprayer (Part 9) by a presser mechanism, which the user needs only to press the push

button once for a continuous water flowing, and another press for stopping the flow.

The mechanism for the presser is accomplished by adjusting the spring inside the body in

which the part of spring will stuck on the body when the push button is pressed.

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 On the other hand, this proposed mechanism has been eliminated, because the user would

face difficulty in reaching the push button since it is placed at the top of the bidet sprayer, which

is so far from the handling part.

2. Combining the parts (1) and (3)

In order to reduce the total number of parts of the current bidet sprayer. We were thinking

in combing the parts (1) and (3) into only one part as shown in Figure , since they are connected

to each other.

Conversely, we have noticed that the combination process would create problems at the

manufacturing stage, because the bidet sprayer has many inner parts, which they would not be able

to assemble it properly if we combine these two parts together as shown in Figure.

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As a result, this proposed improvement on the bidet sprayer has been eliminated.

Final Stage

In this stage, the proposed improvements on the current bidet sprayer have been finalized

in order to increase its functionality as well as reducing its total cost. The proposed improvements

were as follow.

1. Increasing the length of the handle (Part 9)

In order to make the handle reachable for almost all the user, we have increased the handle

length (Part 9). By this improvement, the handle has become better in term of ergonomic

aspects as well as it will not slip from the user’s hand.

2. Increasing the thickness of the handling part (Part 3)

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The body thickness of the current bidet sprayer does not fit properly in the hand. So, we

decided to increase the thickness of the body (Part 3), which can exactly fit the user’s hand.

3. Changing the material of the body

The current bidet sprayer is made from Stainless Steel, which is so heavy as well as it is

very bad in term of thermal absorption. For example, if the flowing water is hot, it will

increase the sprayer temperature, which the user would not be able to handle the bidet. To

add on, the manufacturing cost of the Stainless Steel is quite high.

As a result, we have decided to change the material from Stainless Steel to Plastic. Even

though the durability of plastic is not high compared to stainless steel, but it has so many

advantages such as:

a. Lower manufacturing cost compared to stainless steel

b. Lightweight

c. High thermal absorption

d. Does not rust

4. Changing the material of the thread (Part 10)

We have decided to change the material the thread (Part 10) from Bronze to Brass, which

is cheaper as well as it will not affect the functionality of the bidet sprayer.

5. Adding grooves on the parts (3) and (9)

In order to increase the functionality of the bidet sprayer without increasing its cost, we

have added grooves on part 3 and part 9, which will allow the fingers to fit exactly on the

bidet sprayer without slipping.

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6. Removing the sharp edges.

Since the current bidet sprayer has many sharp edges, we have decided to remove them in

order to increase the safety of the product by minimizing the risk rate from any sudden

action done by the user

7. Reducing the total number of parts

The number of connecting rings in the current bidet sprayer is three, in which can be

combined together to become only one thick part that does the same function. Thus,

the number of assemblies in the manufacturing stage will be reduced which will reduce

the total manufacturing cost.

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Analysis and Evaluation

Design Alternatives

The chosen alternatives for the bidet sprayer design were three products which are available

in the market. As we have discussed the features, advantages, and disadvantages of the popular

bidets on the market today so we can evaluate them and decide on which one could be the proposed

new design. A detailed property of the all the alternatives are explained in the following points.

1. Alternative A

This bidet sprayer is made of high-grade stainless steel which will not rust, so you sure will

be able to keep the toilet looking clean and amazing. It is easy to install and will only take up

minutes to set-up, so there will be no need to hire a professional plumber.

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 Advantages Disadvantages

 The bidet sprayer is made of stainless steel  It does not have an adjustable water

which will not rust. pressure feature.

 There is no need to hire a plumber because  Heavy weight

it is easy to install and will only take up

minutes to be set-up.

 It is compatible with standard toilet tanks.

2. Alternative B

This bidet is multi-purpose as it can be used as a shower sprayer, toilet and bidet cleaner,

or a kitchen sink cleaner. It is made up of stainless steel which makes it durable and rust-proof.

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 It comes with an adjustable water-flow technology, so the user do not have to worry about

overpressure, and it also has a self-closing feature. You can either attach it to the wall or hang it to

the toilet tank.

Advantages Disadvantages

 The bidet sprayer is made of stainless steel  The design is not safe, which has many

which will not rust. sharp edges

 It comes with a T-valve adapter which has

 Heavy weight
been designed to prevent leaks

 It comes with an adjustable water-flow

technology which prevents overpressure.

 It can be mounted on the wall or attached

to the toilet tank.

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 3. Alternative C

This sprayer is made up of heavy-duty polymers which make it leak-free and resistant to

high-pressure. It also comes with a T-valve adapter with water-flow pressure control and an auto

shut-off function. It has an adjustable water pressure feature to function as a bidet sprayer kit, a

hand bidet, a toilet cleaner, and a jet spray.

Advantages Disadvantages

 The sprayer is made up of heavy-duty  It is not made of stainless steel, which is

polymers which make it strong, durable, stronger than polymer.

lightweight, and easy to handle.

 Installation only takes a few minutes, and

there is no need to hire a plumber.

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 4. Alternative D

Our proposed design is made of plastic which make it light weight, resistant to high

temperature as well it has grooves on the body and handle which make it easy to be handled.

Advantages Disadvantages

 The bidet sprayer is made up of plastic  It is not durable enough since it is made of

which make it light weight, cheaper, and plastic

easy to handle.

 It has grooves on the body which makes it

easier to fit the fingers.

 It has rubber rings in the inner body which

prevent the water leakage

Pugh Concept Selection Method

The Pugh chart is a tool used for evaluating multiple options against each other. Rather

than basic consideration of the advantages and disadvantages of each design alternative, the Pugh

chart gives a holistic overview of the needs, goals and other important criteria compared to the

available alternatives.

In order to evaluate the proposed alternatives for bidet sprayer design, the Pugh concept

selection method has been applied, which is shown below in Table, where the chosen datum is the

current bidet design.

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 ALTERNATIVES
CURRENT
CRITERIA
BIDET
A B C D
SAFE
= = + +
DURABLE
D + + - -
WEIGHT
A - - + +
EASY TO
ASSEMBLE T - = + +
RELIABLE U + = - =
COST M = + + +
COMFORT
- = + +
SUM OF (+) 2 2 5 5
SUM OF (-) 3 1 2 1
TOTAL SCORE -1 +1 +3 +4
RANK 4 3 2 1

11-Point Scale

Implementation Stage

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4. CONCLUSION

5. RECOMMENTDATIONS

REFERENCES

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