Download - cost reduction
© Satyam 2009 1Satyam | Integrated Engineering Solutions 1
Welcome to the court of EmperorWelcome to the court of Emperor
Jalaluddin Muhammad AkbarJalaluddin Muhammad Akbar
© Satyam 2009 2Satyam | Integrated Engineering Solutions 2
Noble men! There is a very
important matter before
the court today.
Noble men! There is a very
important matter before
the court today.
The raw material price is shooting up. The material cost of a sword has gone up by
Rs.10 . And …. We are adding 50,000
soldiers to our army this year.
The raw material price is shooting up. The material cost of a sword has gone up by
Rs.10 . And …. We are adding 50,000
soldiers to our army this year.
I want to handle this situation without
increasing the taxes. Please
give your valuable
suggestions as to how we should face
this situation.
I want to handle this situation without
increasing the taxes. Please
give your valuable
suggestions as to how we should face
this situation.
© Satyam 2009 3Satyam | Integrated Engineering Solutions 3
!?
!!??
Why everyone’s quiet?
Birbal! I am surprised that you too have
become silent!!
Why everyone’s quiet?
Birbal! I am surprised that you too have
become silent!!
Your Majesty, I have six ideas
which can reduce the cost of a sword by atleast Rs.20
without compromising the functional requirements.
Your Majesty, I have six ideas
which can reduce the cost of a sword by atleast Rs.20
without compromising the functional requirements.
Brilliant!.Tell us those
ideas.
Brilliant!.Tell us those
ideas.
© Satyam 2009 4Satyam | Integrated Engineering Solutions 4
Presently, the hilt has 7
parts. The proposed design will have 4 .
Presently, the hilt has 7
parts. The proposed design will have 4 .
Existing Design
7 parts
New Idea
4 parts
Part Count
Reduction
© Satyam 2009 5Satyam | Integrated Engineering Solutions 5
For the new hilt,instead of designing
exclusive rivets, we can use the
rivets of daggers.
For the new hilt,instead of designing
exclusive rivets, we can use the
rivets of daggers.
Part Commonisati
on
x
© Satyam 2009 6Satyam | Integrated Engineering Solutions 6
When the Shah of Persia was our
Guest last month ,I observed that the
hilt in his sword does not have a
curved portion. We can design similar
hilts for our experienced
soldiers.
When the Shah of Persia was our
Guest last month ,I observed that the
hilt in his sword does not have a
curved portion. We can design similar
hilts for our experienced
soldiers.
Benchmarking
New IdeaExisting Design
Curved portion
© Satyam 2009 7Satyam | Integrated Engineering Solutions 7
Alternate Material
Blade
Sheath
Copper
Steel
The sheath which houses the blade is
made of copper now.
We can switch over to
Alloy steel which is cheaper.
The sheath which houses the blade is
made of copper now.
We can switch over to
Alloy steel which is cheaper.
© Satyam 2009 8Satyam | Integrated Engineering Solutions 8
Weight Reduction
Blade
Sheath
Since alloy steel is stronger than copper, we can
reduce the thickness by 0.5 mm which will save material
Since alloy steel is stronger than copper, we can
reduce the thickness by 0.5 mm which will save material
2 mm 1.5 mm
© Satyam 2009 9Satyam | Integrated Engineering Solutions 9
Yield ImprovementThe curved
blade design is yielding only 2 pieces per die.
If a straight blade is
designed, we can extract 3
pieces per die.
The curved blade design is yielding only 2 pieces per die.
If a straight blade is
designed, we can extract 3
pieces per die.
2 Blades 3 Blades
© Satyam 2009 10Satyam | Integrated Engineering Solutions 10
Your majesty. The present design is being used since the time of Babur
without any failure. We should not risk any design change.
Your majesty. The present design is being used since the time of Babur
without any failure. We should not risk any design change.
Saheb, there is no doubt that the present sword
designed by you for my
Grandfather’s army is superior. However, let us
test this new design in our
barracks.If they pass the tests, we will deploy them in
the battle field.
Saheb, there is no doubt that the present sword
designed by you for my
Grandfather’s army is superior. However, let us
test this new design in our
barracks.If they pass the tests, we will deploy them in
the battle field.
If the ideas pass the test, we can save atleast Rs. Ten Lakhs this
year, thus serving the
purpose of cost reduction.
If the ideas pass the test, we can save atleast Rs. Ten Lakhs this
year, thus serving the
purpose of cost reduction.
There is an advantage also. I do not have to increase the
tax.
There is an advantage also. I do not have to increase the
tax.
© Satyam 2009 11Satyam | Integrated Engineering Solutions 11
Birbal! I wonder how you
developed these ideas! Is there a systematic way by which others
can also be trained to
generate such ideas.
Birbal! I wonder how you
developed these ideas! Is there a systematic way by which others
can also be trained to
generate such ideas.
Yes, your Majesty. With the help of Functional
Analysis System Technique(FAST) any body can generate such ideas. FAST is a
powerful tool used in Value Engineering (VE) which is an
extremely effective system to improve products and services
for cost and productivity improvement.
Yes, your Majesty. With the help of Functional
Analysis System Technique(FAST) any body can generate such ideas. FAST is a
powerful tool used in Value Engineering (VE) which is an
extremely effective system to improve products and services
for cost and productivity improvement.
If six ideas for the sword itself can
save Rs. Ten lakhs , imagine
how much money we can save on other weapons like
spears, arrows and cannons etc.
If six ideas for the sword itself can
save Rs. Ten lakhs , imagine
how much money we can save on other weapons like
spears, arrows and cannons etc.
© Satyam 2009 12Satyam | Integrated Engineering Solutions 12
Birbal! There are four divisions in my army – Infantry,
Cavalry,Artillery and Elephant brigade. I want you to teach the
engineers in each of these divisions the application of Value Engineering (VE), especially the
Functional Analysis System Technique(FAST). Each division should release Armoury Change Requests (ACRs) for the worth of
Rs.25 lakh.
Birbal! There are four divisions in my army – Infantry,
Cavalry,Artillery and Elephant brigade. I want you to teach the
engineers in each of these divisions the application of Value Engineering (VE), especially the
Functional Analysis System Technique(FAST). Each division should release Armoury Change Requests (ACRs) for the worth of
Rs.25 lakh.
Yes, your Majesty.
Yes, your Majesty.