Professional Documents
Culture Documents
Author
James (Jim) Rains is President of the Advanced Value Group, LLC (AVG). Formed in 2000, AVG
specializes in value engineering and synchronous process improvements (lean manufacturing) in the
factory and/or office environment. He believes in LeanVE. Training in target costing, which includes
Quality Function Deployment and Voice of the Customer is also a part of AVGs long list of services. Jim
has been recently trained by Yoshihiko Sato to conduct Japanese style competitive benchmarking teardown workshops. This workshop integrates the Design for Assembly methodology. Jim has conducted
numerous construction-oriented VE workshops throughout the Middle East. He has also worked in Korea,
China, Australia and many European countries. Jim is retired after more than thirty-one years with
General Motors. He has served on the SAVE International Board of Directors in several capacities,
including President and Chairman. Mr. Rains became a Certified Value Specialist in 1988 and is
currently a Life - CVS. He was elected into the SAVE International College of Fellows in 2002. He is
Chairman of the Board of the Lawrence D. Miles Value Foundation Board of Directors and serves on its
Executive Committee.
Jim has facilitated over 750 projects over a 32 year period. Just in the past ten years he has worked with
over 50 different top global companies. These projects conducted in 15 different countries obtain
significant results by adding value and profit for manufacturing businesses. In addition he has achieved
superb results for US government projects and international construction projects.
Abstract
The primary objective of function analysis is to find the functions/areas of the project that have the best
opportunity to improve value, or in other words which functions should be worked on in the creative phase.
The early VA/VE pioneers like Larry Miles and Carlos Fallon discussed the worth of functions. Later it
seems that the value index formula used today derived from their thoughts, with Don Parker for one,
contributing to its use. For many years people have tried to use the value index as a way to determine
those functions. The value index is defined as a ratio that expresses function cost to function worth.
Function cost is determined during the function analysis phase by allocating cost of the elements of a
project across the functions that each element performs. The result is the total cost of each function in
the project. Function worth is defined by SAVE as the lowest overall cost to perform the function without
regard to criteria or codes. The recommended ways to determine function worth will be discussed in this
paper, but it is the authors opinion that none of the recommended methods offer a real value to the VM
practitioner. In fact, in most cases it leads one to make an error in which functions should be a priority in
the creative phase.
Thus the purpose of this paper will be to:
Introduction
The main purpose of the Function Analysis Phase is to identify the areas that have the best
opportunity to improve value. Function allows the viewing of a product, process or service objectively
in terms of what it does, and must do, rather than in terms of what it currently is. Function allows people
of diverse technical backgrounds, the key decision makers, to communicate and understand each other
and the product, process or service simply and clearly in a common language void of technical jargon.
Thus regardless of ones technical background the people that participate together in a value study will
gain a common understanding of the project they are engaged in. This common understanding is a key
benefit of the Function Analysis Phase.
Function evaluation is the heart of Value Analysis. While the techniques of cost visibility identify high cost
areas, function evaluation techniques make clear, by relating cost to function, what part of high cost is
unnecessary.
Value Analysis is not a simple formula, but rather a skillful application of recognized techniques that
require initiative, creativity, new knowledge and past experience to get appropriate costs for needed
functions. It needs to be noted that the Techniques of Function Evaluation apply equally to products and
services, manufacturing processes and paperwork systems.
There are four main steps to the Function Analysis Phase:
Random Function Identification
Function Analysis System Technique (FAST) Diagram
Cost to Function Allocation
Calculate the Value Index
This paper will discuss the final step of the function analysis phase: the Value Index.
In an email while preparing this paper, Don Parker writes, Fallon favored worth/cost so that the decimal
results could be compared with each other and the one closest to 1.0 would be the better value. Author
note: that this is not function worth and function cost as the current value index definition uses.
I advocated to change this around so that the value index would be cost/worth as shown on page 30, of
VE Theory published in 1977. By having an index of say - 1.88, I thought it easier for one to visualize and
say that there was a potential for 88% improvement in comparison to an index of 1.63 indicating potential
for a 63% improvement. The same indexes done Fallon's way would be 0.12 and 0.37 which is harder for
me to reflect on. I had specific discussions with both Miles and Fallon regarding this and they both fully
reviewed, edited, and approved the VE Theory text.
I agree with Don Parker and prefer the equation:
Function Cost
Value Index
Function Worth
Don also writes in, Value Engineering Theory (page 30). Remembering that cost and worth are related
to functions rather than items, the index serves to:
1. Assist in determining whether to proceed with the value study. The study should proceed only if
poor value, indicated when the value index is grater than one, exists. Good value is indicated
when the index is one.
2. Locate areas where cost/worth ratio is the greatest. Generally these areas will have the greatest
VE potential and are useful items for VE study.
3. Provide a factor for measuring the effectiveness of any VE efforts. Did the ratio approach unity
after the VE effort?
According to the SAVE International Value Methodology Standard and Body of Knowledge the current
definitions are:
VALUE INDEX: A ratio that expresses function cost function worth. This ratio used to determine the
opportunity for value improvement which is usually identified in the Function Analysis
Phase.
FUNCTION COST: The expenditure of resources to perform the function.
FUNCTION WORTH: The lowest overall cost to perform a function without regard to criteria or codes.
AUTHOR NOTE: This is radically different than the definition used by Miles.
1. Understanding: Until a team struggles through cost allocation decisions, it will have an imperfect
understanding of the functions involved.
2. Detailed Analysis: A team is forced to go into every nook and cranny of the design and force each
element of the product or process to justify its existance.
3. Overview: At the end of the function cost allocation, the team sees the overall view of where the
costs are by function.
4. Creativity: The teams subconscious mind is loaded with very usable data for later creativity and
is now prepared to determine value mis-match.
To not do cost function allocation in any VE study in my mind simply isnt VE. The learning and
understanding that happens across every team member significantly helps them in the creative phase,
where the ideas that eventually get implemented come from.
The text in the book stated that the team worked on the two highest value index functions; Find Records
and Admit Patient. While I am not sure exactly how the team determined the function worth, I do know
they neglected the highest cost function which is Store Data. This function also had the highest
variance between the time allocated to that function and the estimated time for the function worth.
The table below shows the time differences.
Thus I feel by only looking at the value index as a method of determining which functions should receive
attention during the creative phase is a big mistake. There may be functions that need to be improved
regardless of their cost or value index.
To help explain my method I need to show an example of a costed FAST diagram of a high tech
instrument cluster that is used in an instrument panel (dash board) of a new vehicle. Note that the costs
have been converted to percentages to disguise the manufacturers real costs.
Based on the team objectives that almost always includes cost reduction, performance issues, quality
issues and customer issues it was decided to select the following functions for the creative phase.
Improve appearance 16.6%
Join shapes 6.3%
Transmit power/signals 8.1%
Control operation 6.1%
Transmit/Direct light 6.4%
Indicate position 9.7%
Thus just these six functions (out of a total of 38) totaled 53.2% of the total cost. It must be stated that
since other functions are caused by or happen the same time as some of these functions and there are
several lower order functions that will be impacted by how these functions are performed, the real
impacted cost is much higher. It took less than 5 minutes for me to decide with the team which functions
to focus on in the creative phase. The team results from the study were tremendous. Since the company
that did the study was just in the early design development phases they were competing with other
suppliers to gain this business. With the results of the study the automotive supplier was able to offer the
customer a more competitive quote that eventually earned them the new business. The summary of the
results were:
References
Management Application of Value Engineering, Donald E. Parker, Miles Value Foundation, Page 92
Value Engineering Theory and Practice in Industry, Thomas R. King, 2000, Miles Value Foundation,
General reference
Value Analysis, Carlos Fallon, 1986, Miles Value Foundation, Pages 33 - 34
Value Engineering Theory, Donald E. Parker, 1977, Miles Value Foundation, Page 30
Techniques of Value analysis and Engineering, Lawrence D. Miles, 1989, Miles Value Foundation, Pages
44 and 49.
Module I Workshop Workbook, James Rains, Pages 30,44,45.
Welcome to Value Analysis and Value Engineering Thomas F. Cook ,1984 SAVE Conference
Proceedings