Value Engineering and Value Analysis
Value Engineering and Value Analysis
Value engineering uses rational logic (a unique "how" - "why" questioning technique) and the analysis of
function to identify relationships that increase value. It is considered a quantitative method similar to the
scientific method, which focuses on hypothesis-conclusion approaches to test relationships, and operations
research, which uses model building to identify predictive relationships.
An item that does its function better than another, has more value. Between two items that perform their function
equally well, the one that costs less is more valuable.
The "performance of its function" could include that it is beautiful (where needed). Do not be surprised if as a
result of value analysis the cost of an item is less than half of its previous cost.
Value engineering began at General Electric Co. during World War II. Because of the war, there were shortages
of skilled labour, raw materials, and component parts. Lawrence Miles, Jerry Leftow, and Harry Erlicher at G.E.
looked for acceptable substitutes. They noticed that these substitutions often reduced costs, improved the
product, or both. What started out as an accident of necessity was turned into a systematic process. They called
their technique value analysis.
It is particularly suited to physical and mechanical problems, but can also be used in other areas.
A "basic function"
It is anything that makes the product work or sells. A function that is defined as "basic" cannot
change.
Secondary functions
It is also called "supporting functions", described the manner in which the basic function(s)
were implemented. Secondary functions could be modified or eliminated to reduce product cost.
Seek improvements
Eliminate or reduce the cost of components that add little value, especially high-cost components.
Enhance the value added by components that contribute significantly to functions that are particularly
important to customers.
As VA progressed to larger and more complex products and systems, emphasis shifted to "upstream" product
development activities where VA can be more effectively applied to a product before it reaches the production
phase. However, as products have become more complex and sophisticated, the technique needed to be adapted
to the "systems" approach that is involved in many products today. As a result, value analysis evolved into the
"Function Analysis System Technique" (FAST) which is discussed later.
One objective of value analysis or function analysis, to improve value by reducing the cost-function relationship
of a product, is achieved by eliminating or combining as many secondary functions as possible. Thus, the value
analysis method is based on defining the functions of what to be accomplished and the cost to perform it.
Also, identifying the function in the broadest possible term provides the greatest potential for divergent thinking
because it gives the greatest freedom for creatively developing alternatives. A function should be identified as to
what is to be accomplished by a solution and not how it is to be accomplished. How the function is identified
determines the scope, or range of solutions that can be considered.
The functions designated as "basic" represent the operative function of the item or product and must be
maintained and protected. Determining the basic function of single components can be relatively simple. By
definition then, functions designated as "basic" will not change, but the way those functions are implemented is
open to innovative speculation.
Importance of cost
As important as the basic function is to the success of any product, the cost to perform that function is inversely
proportional to its importance. This is not an absolute rule, but rather an observation of the consumer products
market.
Few people purchase consumer products based on performance or the lowest cost of basic functions alone. When
purchasing a product it is assumed that the basic function is operative. The customer's attention is then directed
to those visible secondary support functions, or product features, which determine the worth of the product.
From a product design point of view, products that are perceived to have high value first address the basic
function's performance and stress the achievement of all of the performance attributes. Once the basic functions
are satisfied, the designer's then address the secondary functions necessary to attract customers. Secondary
functions are incorporated in the product as features to support and enhance the basic function and help sell the
product. The elimination of secondary functions that are not very important to the customer will reduce product
cost and increase value without detracting from the worth of the product.
The cost contribution of the basic function does not, by itself, establish the value of the product. Few products
are sold on the basis of their basic function alone. If this were so, the market for "no name" brands would be
more popular than it is today. Although the cost contribution of the basic function is relatively small, its loss will
cause the loss of the market value of the product.
FAST permits people with different technical backgrounds to effectively communicate and resolve issues that
require multi-disciplined considerations.
FAST builds upon VA by linking the simply expressed, verb-noun functions to describe complex systems.
FAST is not an end product or result, but rather a beginning. It describes the item or system under study and
causes the team to think through the functions that the item or system performs, forming the basis for a wide
variety of subsequent approaches and analysis techniques. FAST contributes significantly to perhaps the most
important phase of value engineering: function analysis. FAST is a creative stimulus to explore innovative
avenues for performing functions.
The FAST diagram or model is an excellent communications vehicle. Using the verb-noun rules in function
analysis creates a common language, crossing all disciplines and technologies. It allows multi-disciplined team
members to contribute equally and communicate with one another while addressing the problem objectively
without bias or preconceived conclusions.
With FAST, there is no right or wrong model or result. The problem should be structured until the product
development team members are satisfied that the real problem is identified. After agreeing on the problem
statement, the single most important output of the multi-disciplined team engaged in developing a FAST model
is consensus. Since the team has been charged with the responsibility of resolving the assigned problem, it is
their interpretation of the FAST model that reflects the problem statement that's important. The team members
must discuss and reconfigure the FAST model until consensus is reached and all participating team members are
satisfied that their concerns are expressed in the model. Once consensus has been achieved, the FAST model is
complete and the team can move on to the next creative phase.
When studying systems it becomes apparent that functions do not operate in a random or independent fashion. A
system exists because functions form dependency links with other functions, just as components form a
dependency link with other components to make the system work.
The importance of the FAST approach is that it graphically displays function dependencies and creates a process
to study function links while exploring options to develop improved systems.
There are normally two types of FAST diagrams, the technical FAST diagram and the customer FAST diagram.
A technical FAST diagram is used to understand the technical aspects of a specific portion of a total product. A
customer FAST diagram focuses on the aspects of a product that the customer cares about and does not delve
into the technicalities, mechanics or physics of the product. A customer FAST diagram is usually applied to a
total product.
The essential logic associated with the FAST HOW-WHY directional orientation when undertaking any task is:
Start with the goals of the task, and then
Explore methods to achieve the goals.
A systems diagram starts at the beginning of the system and ends with its goal. A FAST model, reading from left
to right, starts with the goal, and ends at the beginning of the "system" that will achieve that goal.
Second, changing a function on the HOW-WHY path affects all of the functions to the right of that function.
This is a domino effect that only goes one way, from left to right. Starting with any place on the FAST model, if
a function is changed the goals are still valid (functions to the left), but the method to accomplish that function,
and all other functions on the right, are affected.
Finally, building the model in the HOW direction, or function justification, will focus the team's attention on
each function element of the model. Whereas, reversing the FAST model and building it in its system orientation
will cause the team to leap over individual functions and focus on the system, leaving function "gaps" in the
system. A good rule to remember in constructing a FAST Model is to build in the HOW direction and test the
logic in the WHY direction.
The vertical orientation of the FAST model is described as the WHEN direction. This is not part of the intuitive
logic process, but it supplements intuitive thinking. (WHEN) is not a time orientation, but indicates cause and
effect.
Scope lines represent the boundaries of the study and are shown as two vertical lines on the FAST model. The
scope lines bound the "scope of the study", or that aspect of the problem with which the study team is concerned.
The left scope line determines the basic function(s) of the study. The basic functions will always be the first
function(s) to the immediate right of the left scope line.
The right scope line identifies the beginning of the study and separates the input function(s) from the scope
of the study.
The objective or goal of the study is called the "Highest Order Function", located to the left of the basic
function(s) and outside of the left scope line. Any function to the left of another function is a "higher order
function". Functions to the right and outside of the right scope line represent the input side that "turn on" or
initiate the subject under study and are known as lowest order functions. Any function to the right of another
function is a "lower order" function and represents a method selected to carry out the function being addressed.
Those function(s) to the immediate right of the left scope line represent the purpose or mission of the product or
process under study and are called Basic Function(s). Once determined, the basic function will not change. If the
basic function fails, the product or process will lose its market value.
All functions to the right of the basic function(s) portray the conceptual approach selected to satisfy the basic
function. The concept describes the method being considered, or elected, to achieve the basic function(s). The
concept can represent either the current conditions (as is) or proposed approach (to be). As a general rule, it is
best to create a "to be" rather than an "as is" FAST Model, even if the assignment is to improve an existing
product. This approach will give the product development team members an opportunity to compare the "ideal"
to the "current" and help resolve how to implement the differences. Working from an "as is" model will restrict
the team's attention to incremental improvement opportunities. An "as is" model is useful for tracing the
symptoms of a problem to its root cause, and exploring ways to resolve the problem, because of the dependent
relationship of functions that form the FAST model.
Any function on the HOW-WHY logic path is a logic path function. If the functions along the WHY direction
lead into the basic function(s), than they are located on the major logic path. If the WHY path does not lead
directly to the basic function, it is a minor logic path. Changing a function on the major logic path will alter or
destroy the way the basic function is performed. Changing a function on a minor logic path will disturb an
independent (supporting) function that enhances the basic function. Supporting functions are usually secondary
and exist to achieve the performance levels specified in the objectives or specifications of the basic functions or
because a particular approach was chosen to implement the basic function(s).
Independent functions describe an enhancement or control of a function located on the logic path. They do not
depend on another function or method selected to perform that function. Independent functions are located above
the logic path function(s), and are considered secondary, with respect to the scope, nature, level of the problem,
and its logic path. An example of a FAST Diagram for a pencil is shown below.
Clustering functions involves drawing boundaries with dotted lines around groups of functions to configure sub-
systems. Clustering functions is a good way to illustrate cost reduction targets and assign design-to-cost targets
to new design concepts. For cost reduction, a team would develop an "as is" product FAST model, cluster the
functions into subsystems, allocate product cost by clustered functions, and assign target costs. During the
process of creating the model, customer sensitivity functions can be identified as well as opportunities for
significant cost improvements in design and production.
Following the completion of the model, the subsystems can be divided among product development teams
assigned to achieve the target cost reductions. The teams can then select cost sensitive sub-systems and expand
them by moving that segment of the model to a lower level of abstraction. This exposes the detail components of
that assembly and their function/cost contributions.
1. Capture customer requirements and perform QFD product planning with the product planning matrix.
Translate customer needs into directly into verb-noun functions or use a second matrix to translate
technical characteristics into verb-noun functions.
2. Prepare a FAST diagram and develop the product concept in conjunction with the QFD concept
selection matrix. Review the verb-noun functions in the QFD matrix and assure that they are included in
the FAST diagram. Revise verb-noun function descriptions if necessary to assure consistency between
the QFD matrix and the FAST diagram.
3. Dimension the system in the FAST diagram into subsystems/assemblies/parts. These are generically
referred to as mechanisms.
4. Develop value analysis matrix at system level. The "what's" or system requirements/function in the
value analysis matrix are derived from either a customer (vs. technical) FAST diagram or by selecting
those function statements that correspond to the customer needs or technical characteristics in the
product planning matrix. The importance rating is derived from the product planning matrix as well.
5. Complete the value analysis matrix by relating the mechanisms to the customer requirements/functions
and calculate the associated weight. Summarize the column weights and normalize to create mechanism
weights. Allocate the target cost based on the mechanism weights. This represents the value to the
customer based on the customer importance. Compare with either estimated costs based on the product
concept or actual costs if available.
6. Identify high cost to value mechanisms / subsystems by comparing the mechanism target costs to the
mechanism estimated/actual costs
A product or system such as an automobile contains a great many components and would result in an extremely
complex FAST model. The complexity of the process is not governed by the number of components in a
product, but the level of abstraction selected to perform the analysis. With an automobile, a high level of
abstraction could contain the major subsystems as the components under study, such as: the power train, chassis,
electrical system, passenger compartment, etc. The result of the FAST model and supporting cost analysis might
then focus the team's attention on the power train for further analysis. Moving to a lower level of abstraction, the
power train could then be divided into its components (engine, transmission, drive shaft, etc.) for a more detailed
analysis.
In other words, the concept of decomposition is applied to a FAST model. The initial FAST model will stay at a
high level of abstraction. Starting at a higher level of abstraction allows for uncluttered macro analysis of the
overall problem until those key functions can be found, isolated, and the key issues identified. If a function is
identified for further study, we note that with a "^" below the function box. A supporting FAST diagram is then
created for that subsystem function. This process of decomposition or moving to lower levels of abstraction
could be carried down several levels if appropriate.
Once high cost to value mechanisms is identified in the initial system value analysis matrix, the next step is to
focus more attention on those mechanisms and associated functions. Dimensioning groups the functions together
into those associated with a particular subsystem, assembly or part. The FAST diagram can be expanded into a
lower level of abstraction in the area under investigation. The steps involved are as follows:
The QFD Concept Selection Matrix is a powerful tool to evaluate various concept and design
alternatives based on a set of weighted criteria that ultimately tie back to customer needs.
Benchmarking competitors and other similar products helps to see new ways functions can be
performed and breaks down some of the not-invented-here paradigms.
Product cost and life cycle cost models support the estimating of cost for the Function-Cost
and Value Analysis Matrices and aid in the evaluation of various product concepts.
Technology evaluation is leads us to new ways that basic functions can be performed in a
better or less costly way. Concept development should involve people with a knowledge of new
technology development and an open mind to identify how this technology might relate to
product functions that need to be performed. Methods such as the theory of inventive problem
solving or TRIZ are useful in this regard.
Design for Manufacturability/Assembly principles provide guidance on how to better design
components and assemblies that are more manufacturable and, as a result, are lower in cost.
Value Analysis or Function Analysis provide the methods to identify the problem and to begin to define the
functions that need to be performed. As we proceed in developing a FAST model, implicit in this process is
developing a concept of operation for the product which is represented by all of the lower order functions in a
FAST diagram.
Concept alternatives will be developed through brainstorming, benchmarking other products performing similar
functions, and surveying and applying new technology. Since multiple concepts need to be evaluated, we want to
use a higher level of abstraction for the FAST model to provide us with the greatest flexibility and a minimum
level of effort. Trade studies and technical analysis will be performed to evaluate various product concepts. A
concept selection matrix is a good tool to summarize a variety of different data and support making a decision
about the preferred concept.
All of these steps may be iterative as a preferred concept evolves and gets more fully developed. In addition,
there should be a thorough evaluation of whether all functions are needed or if there is a different way of
accomplishing a function as the concept is developed to a lower level of abstraction. When a Function Cost or
Value Analysis Matrix is prepared, functions that are out of balance with their worth are identified, further
challenging the team to explore different approaches.
SUMMARY
Value analysis and its more robust cousin, Function Analysis System Technique, are important analysis tools.
These methodologies lead to improved product designs and lower costs by:
Providing a method of communication within a product development team and achieving team
consensus
Facilitating flexibility in thinking and exploring multiple concepts
Focusing on essential functions to fulfill product requirements
Identifying high cost functions to explore improvements
References
1. ^ Value Methodology Standard
2. ^ Text of Law Requiring Value Engineering in Executive Agencies
3. ^ The Value Methodology Standard. SAVE International. http://www.value-
eng.org/catalog_monographs.php.
4. ^ SAVE International - Value Engineering, Value Analysis, Value Management and Value
Methodology
Further reading
Cooper, R. and Slagmulder, R. (1997): Target Costing and Value Engineering.
Akiyama, Kaneo. Function Analysis: Systematic Improvement of Quality and Performance. Cambridge,
MA: Productivity Press, Inc., 1991.
Emblemsvag, Jan. Life-Cycle Costing: Using Activity-Based Costing and Monte Carlo Methods to
Manage Future Costs and Risks. New York: John Wiley & Sons, 2003.
Fleisher, Craig S., and Babette Bensoussan. Strategic and Competitive Analysis: Methods and
Techniques for Analyzing Business Competition. Englewood Cliffs, NJ: Prentice-Hall, 2002.
Have, Ten Steven. Key Management Models. Englewood Cliffs, NJ: Prentice-Hall, 2002.
Shillito, M. Larry, and David J. De Marle. Value: Its Measurement, Design and Management. New
York: Wiley-Interscience, 1992.
Trischler, William E. Understanding and Applying Value-Added Assessment: Eliminating Business
Process Waste. Milwaukee, WI: ASQC Quality Press, 1996.
"Value Engineering - Concepts, Techniques and Applications by Anil Kumar Mukhopadhyaya"
"Value Engineering Mastermind - From Concept to Value Engineering Certification by Anil
Kumar Mukhopadhyaya"
"Value Optimization for Project and Performance Management by Robert B. Stewart, CVS-
Life, FSAVE, PMP"
External links
Lawrence D. Miles Value Foundation
Lawrence D. Miles Value Engineering Reference Center: Wendt Library
SAVE International - Value engineering society
wertanalyse.com - Many links regarding VE organisations and publications
The Canadian Society of Value Analysis - Value Engineering in Canada
Value Engineerings History in Construction- American Institute of Architects - AIA