VALUE ENGINEERING

in the Lean Environment!

Dave Love
Value Engineering Project Mgr
10 MAY 2007
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Distribution Statement A: Approved for public release; distribution unlimited.

VE in the Lean Environment

Value Engineering
Workshop

6 8 February 2007

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Distribution Statement A: Approved for public release; distribution unlimited.

VE in the Lean Environment

Function Analysis System Technique (FAST) Problem ID

Why

How

Obsolescence
Study

Health Analysis
& Assessment

Cost
Modeling
Technology
Trending

Problem
Identification
(Sustainment
Need)

Parts
Data

Sustainment
Plan

Vendor Interviews,
Component Availability
Software, Inventory,
Service Life and Systems
Population

Industry
Standards
Groups, Market
Study Reports

Field Failure
Analysis
Trending

Customer
Communication,
Logistical RM&A
Data Bases

Parts
Derating

Structural, Thermal,
& Material Analysis

Reliability
Analysis

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Distribution Statement A: Approved for public release; distribution unlimited.

Need to Predict
Sustainment
Requirements

VE in the Lean Environment

How

Function Analysis System Technique

(FAST) BCA
Why
Tech
Refresh
Insertion

Trade, Market
&
Requirements
Study

Technology
Solution

Engineering
Solution

Form Fit
Function

Redesign

BCA

Analysis of
Alternatives

Trade,
Market, &
Requirements
Study

Technology
Solution

Redesign

Sustainment
Work
Assessment
Teams

Reverse
Engineer
Life of Type
or Bridge
Buy
Logistical
Solution
Alternative
Substitution

Component
Analysis

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Distribution Statement A: Approved for public release; distribution unlimited.

Problem ID
(Sustainment
Need)

Goals and Objectives

Define sustainment engineering
Define systematic process to determine
customers sustainment issues
Systematic approach to Analysis of
Alternatives (AoA)
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Breakthroughs
The ability to identify functions and the
application to the Value Stream Analysis
Credible definition of Sustainment
Engineering
Gaps in sustainment analysis consisting of
Reliability Analysis and Sustainment
Planning
Identification of disconnection between
capabilities within the Organization
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Distribution Statement A: Approved for public release; distribution unlimited.

Next Steps

Value Engineering Workshop findings

provided as input to LEAN VSA
Reliability Analysis
Sustainment Plan
Sustainment Engineering Process

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Enterprise Innovation VSA

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Cost Drivers
April 2002 thru March 2003
Item Name

% Total
Failures

% Total
Populatio
n

Qty

Unit $

Total $

Output TWT

39

2.6

342

$4258

$1341.7K

HVDU

5.3

41

$4645

$299.2K

HVPS

6.8

53

$4466

$267.0K

RF Mod B2

0.9

49

$4719

$173.5K

Tape Drive

10.3

17

$3481

$129.6K

RF Mod B3

0.2

26

$3459

$87.9K

$14504

$76.0K

RFMU
RF Switch (2x32)

4.1

15

$4879

$72.1K

Yig Flt BD3 CCA

2.2

$14571

$42.9K

Other

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System Level Totals

9

1280

$930.6K

1832

$3420.5K

Cost per System

Distribution Statement A: Approved for public release; distribution unlimited.

$41.7K

Reliability Drivers
April 2002 thru March 2003
Item Name

%CA of Total

CAs

MTBF

HVDU

76

10,000

Tape Drive

17

13,000

HV Relay Control

19

21,000

Pump Motor

24,000

Keyboard

31,000

Hard Disk System

44,000

865

970

System Level
Totals

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Supportability Drivers
April 2002 thru March 2003
System Level Ao = 0.67 (Last 12 Months)
Item Name

NL

MLT

Tot Log

%NO New System Ao

B
(w/ no log. Delay

* Output TWT

145

250

35,862

73

0.674

HVDU

19

310

6,580

53

0.673

HV Relay Control

14

290

4,044

82

0.671

HVPS

12

260

3,124

24

0.671

Tape Drive

340

2,414

41

0.675

System Level
Totals

533

530

183,489

62

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Distribution Statement A: Approved for public release; distribution unlimited.

Maintenance Drivers
April 2002 thru March 2003
Item Name

% of Total Hrs

CA

MTTR

TOT CM
(Hrs)

HVDU

13

76

6.0

457.9

HVPS

10

65

5.8

376.2

* Output TWT

200

1.0

198.5

Tape Drive

17

7.5

128.2

Output TWT

30

3.1

92.3

Other

65
865

11.0

3609.3

System Level Totals

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Traveling Wave
Tube

TWT

Doubled TWT Life

Reduced Supply Demand by 190 Units per Year
Estimated Cost Avoidance of $ 2.8 M/Yr
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VE in the Lean Environment

Value = Function (VE) / Cost (Lean)

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Distribution Statement A: Approved for public release; distribution unlimited.

VE in the Lean Environment

Together
Value Engineering and Lean
Produce Synergy!

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