3/15/2012 1

Value Analysis/ Engineering

in Product Design

3/15/2012 2

Labor

LandCapital

Industri

……industri adalah lokasi (tempat) dimana aktivitas produksi akan

diselenggarakan ………

Aktivitas produksi…sekumpulan aktivitas yang diperlukan untuk merubah

satu kumpulan masukan (inputs) menjadi produk luaran akhir (finished

goods output) yang memiliki nilai tambah

3/15/2012 3

Aktivitas Produksi

Ditinjau dari Proses

Aliran Uang

Income(Before tax)

Modal Kerja(Working capital)

Long Term

Capital Assets

Proses Distribusi & Pemasaran/Penjualan(Proses Konversi Produk Menjadi uang)

Proses Produksi / Operasional(Proses Konversi Uang Menjadi Produk yang Memiliki Nilai Tambah)

Finished Goods Product

Tax Divedends Bhn Baku

Tenaga

Kerja Energi

Informasi, dll Capital

(Depresiasi)

3/15/2012 4

3/15/2012 5

Pergeseran Paradigma Bisnis-Industri

Era Industri Era Informasi

Perubahan lamban

Lokal

Hard technology

Tangible asset

Arm-length transaction

Functional

Product life-cycle lama

Kekuatan otot

Perubahan cepat

Global

Soft technology

Intangible asset

Closed Supplier-Customer

Cross functional

Product life-cycle pendek

Kekuatan otak

3/15/2012 6

Perkembangan Atribut Kompetisi

Cost Quality DeliveryFlexibility/

ResponsivenessInnovation

1800 1960 1970 1980 1990 2000

3/15/2012 7

Produktivitas, Unit Costs & Daya Saing

t1

1997

t2

2002

P1

P2

P C

t1

1997

t2

2002

UC1

UC2

3/15/2012 8

Areas of Opportunities for Productivity Improvement- Education & Training

- Development of Work Methods

- Attitude & Motivation

- Performance Related Pay

- Working Environment

- Inventory Controll

- Cash Management

- Investment Analysis

- Economic Planning & Control

- Production Planning & Control

- Plant Layout & Matrial handling

- Cost & Quality Control

- Manufacturing Method Analysis

- Maintenance Scheduling

- Company Strategy

- Organizational Development

- Management Development

- Administration Rationallization

- Manpower Analysis

- General Market Analysis

- Market Segmentation

- Manufacturing & Price Strategy

- Distrbution Analysis

- Organization of Marketing Function

- Product Planning & Development

- Product Profitability

- Value Engineering & Analysis

Employee

Production

Capital

Productivity

Production

Productivity

Organization

Productivity

Sales Market

Productivity

Product

Productivity Imp

rov

ed

Co

mp

eti

tiv

e

Po

sit

ion

an

d P

rofi

t

3/15/2012 9

Engineering EconomyPengambilan keputusan yang berkaitan

dengan evaluasi proyek dan kelayakan alternatif ditinjau dari aspek teknis-ekonomis

(tekno-ekonomi)Technical

Aspect

Design

Alternatif

Economical

Aspect

Engineering

Project

The Best

Solution

Alternative

Functional

Economics/ Cost

3/15/2012 10

Engineering Project Evaluation

• Analisa keputusan berdasarkan pertimbangan ekonomis

(costs/money term) dengan aspek teknis (technological/

engineering) sebagai dasar pertimbangan utamaanya

• Proses pengambilan keputusan untuk alternatif (1) pembelian mesin baru

(manual >< semi-automatics, etc), (2) make-or-buy analysis (ownership

><leasing), dan (3) product design (over design >< simple design)

Engineering

Proposal

Production

Or

Construction

Demand

Satisfaction

Efisiensi = Output/Input

(teknis/fungsi)

Proses Nilai Tambah Efisiensi = Worth/Costs

(ekonomis)

3/15/2012 11

PROFIT

Traditional Cost & Product Price Structure

Distribution & Administration

Selling & Advertising

Fixed & Miscellaneous

Indirect Labor

Indirect Material

Direct Labor

Direct Material

Selling

Price

Prime

Costs

Overhead

Costs

Cost of Goods

Manufactured

Costs of

Goods Sold

3/15/2012 12

Product (Selling) Price ? Prime Cost = Direct Material Costs

+ Direct Labor Costs

Factory Overhead Costs = Indirect Material Costs (factory

supplies, lubricants, etc.) + Fixed & Miscellaneous Expenses (rent,

insurance, taxs, depreciation, engineering, R & D, maintenance &

Repairs, power, light, heat, etc.)

Cost of Goods manufactured = Prime Costs + Factory Overhead

Costs

Commercial Expenses = Distribution Expenses (advertising,

samples, trevel/transportation, rents, auditing, etc.)

Selling Price (Before Taxes) = CGM + CE + SC + Profit

3/15/2012 13

Value Analysis & Engineering value is a fair return for goods, services or money

Penghargaan (Worth) yang diberikan untuk sebuah obyek, produk atau

pun jasa (ditinjau dari aspek fungional maupun ekonomisnya)

Formulasi : Value = =

Function (s) (+)

Costs (-)

Value Analysis (VA)/Value Engineering (VE) = Cost Reduction Program

(more product’s function for less money)

VA – cost reduction program (cost prevention) sebelum proses

manufacturing contruction (saat tahap perancangan)

VE – cost reduction program saat awal dan selama proses mfg

berlangsung

3/15/2012 14

Design

Direct Material Costs

Others

Product

Specification

Product

Specification

Production Processes

Indirect Material Costs

Jigs, Fixtures &

Tooling Costs

Others

VA in Design VA in Production (VE)

3/15/2012 15

Value Analysis & Engineering

Sebuah metode evaluasi untuk mengetahui

kebutuhan atau keputusan customer di dalam mengambil keputusan untuk membeli sebuah produk atau jasa. Evaluasi dilakukan dengan

cara menyususn suatu pendekatan kreatif yang tujuannya menentukan dan mengidentifikasikan biaya-biaya yang tidak perlu

atau pun aktivitas-aktivitas yang tidak produktif dan memberikan nilai tambah terhadap produk/jasa

Faktor-faktor penyebab rendahnya nilai sebuah produk dapat

diidentifikasikan (1) fungsi tidak seperti yang diharapkan, (2) desain

terlalu kompleks dan berakibat processing costs menjadi tinggi, (3)

over design yang menimbulkan produk memiliki fungsi terlalu

banyak yang semuanya tidak merupakan kebutuhan customer

sebenarnya.

3/15/2012 16

Strategi Meningkatkan

Keuntungan (Profit)

Menaikkan harga jual (selling price)

Menaikkan volume penjualan (market share)

Costs Reduction Program (CRP) : (a) menekan

struktur overhead costs, (b) meminimalkan

biaya produksi (processing costs), (c)

mengurangi biaya material (material cost) &

direct labor costs, dan (d) kombinasi ketiga

alternatif tersebut.

3/15/2012 17

Product

Selling

Price

PROFIT

Overhead

Processing/

Manufacturing

Direct Material

&

Direct Labor

PROFIT

Fungsi-2 Tambahan

Yang tidak perlu

Fungsi-2 Tambahan

(over design

Fungsi Penunjang

(Supporting Function)

Fungsi Utama

(basic Function)

Struktur Biaya Produk Value Analysis

Total

Mfg

Costs

Biaya-2

yang bisa

ditekan

Biaya-2

yang

relevan

dengan

fungsi

yang

dihasilkan

Fungsi

Primer

Fungsi

Sekunder

(2)

(1)

(3)

3/15/2012 18

Alternatif-Alternatif

Pengembangan Nilai/Fungsi Produk Klasifikasi fungsi sebuah produk (1) fungsi utama (basic

function) dan (2) fungsi tambahan/sekunder (fungsi

penunjang yang diperlukan dan tambahan fungsi akibat

“complex/ over design”)

Alternatif VA : (1) fungsi tetap, biaya diperkecil (material

substitution, methods improvement, etc.), (2) fungsi

bertambah, biaya tetap, dan (3) fungsi bertambah, biaya

diperkecil.

VA/VE diaplikasikan secara terus menerus

dan mengikuti life-cycle of product

3/15/2012 19

Relation Between VA/VE Activity

& Total Life-Cycle CostsIdea

DevelopmentDesign Production Running

Functional

Requirement

Design

Requirement

Production

Requirement

Product

Output

SE

VA/VEIE/QC QC/SE

Satisfaction

to

Customer

Needs of

Customer

Technical

Level

Planning Cost Control Planning Cost Cont. Planning Cost Cont.

Manufacturer’s Costs Control Customer Running

Costs

Total Cost = Life-Cycle Cost Paid by Customer

3/15/2012 20

VA/VE Job - Plan Information Phase : What is it ? (identify the project, scope

of study, quantities & product life-cycle, marketing requirement,

review cost data, etc.). Resume most significant facts

Analytic Phase : What does it do ? (define the function, identify the

benefits), what does it costs ? (installation, operation & maintenance, down

time, etc.; what should it costs ? (costs per year, costs per piece, etc.

Creative Phase : What will do better ? (innovation, optimization,

simplication, miniaturization)

Evaluation Phase : Pilih alternatif rancangan produk terbaik, seleksi metode

fabrikasi (mfg) yang lebih efektif-efisien, dan bandingkan pilihan-pilihan yang

bisa diberikan melalui implementasi VA/VE

Recommendations & Implementations