New RBD VE Procedures Processes for Refrigerator Ice Making Products Creating $70 million of New Market Revenues, Cost Reduction of 27.4, Energy Savings of 86, Parts Reduction of 50, and Creating Life Cycle Value of $590 million

摘要

The Korea's best ice maker manufacturer with $150 million revenues utilizing VE/VM methods is leading the global refrigerator ice making with new market revenue generation of $70 million, cost reduction of 27.4%, energy saving of 86%, parts reduction of 50%, and creating life cycle value of $590 million. Low-end technology ice makers are trying to survive in the low margin refrigerator market as OEM suppliers. However, this company exceeds the global requirements by transforming the conventional R&D(Research & Development) to R&BD(Research & Business Development) organization by implementing VE/VM strategies throughout the new product development. This organization transformation has evolved by focusing on the company-wide procedures and processes by implementing VE/VM specific tools streamlining the research and development projects and developing into results-oriented VE projects, which must first align customization of project objectives coupled with necessary streamlining processes. The Research & Business Development VE projects must have results-oriented objectives classified as production cost reduction, cost of ownership, technology convergence, intangible results, and life cycle value. The production cost reduction consists of outsourcing, miniaturization, mass production, parts reduction or DFA, and DFMA. For the life time of the product ownership, energy and maintenance costs can be reduced. The VE projects can be aligned with technology convergence, including bimetallic material, sensor or system integration, non-metallic, integration of the state-of-the-art material, or AC/DC power system. Each VE project can have a different set of objectives with different measure of importance weight. With these VE project objectives assigned, VE/VM tools can be streamlined accordingly. To achieve these procedures and processes, this company has over 40% of VE/VM specialists in the research and development organization. Not only this company provides quality ice makers to the premier customers, but also it fulfills the future needs and demands of the consumers offering very critical differentiation competitive edge in the global market. In this paper, a number of successful VE projects are discussed how results-oriented and different objectives streamlined and processed to achieve superior outcomes of both tangible and intangible results. To produce the world class results, the VE/VM methods are utilized extensively. The Enhanced FAST with Sensitivity Matrix is used for enterprise level planning during the implementation phase. After defining the functions, the FAST, Function Analysis and Value Indexing using Paired Comparison Analysis are used in streamlining the functions and processes resulting in cost reduction of 27.4%. Also, the new technology convergence with TRIZ technical & physical contradictions solutions creating over $70 million per year for the new market establishment, parts reduction of 50%, and energy saving of 86%. These VE projects result in life cycle value of over $590 million. The most important performance of VE/VM is to institute an entire organization with innovative minds and commitments focusing on the human aspects pursuing the excellence of VE/VM producing VE/VM specialists who contribute for the best of the company as well as in the society by increasing the intellectual capabilities tremendously. In order to prepare for the long-term sustaining growth, instituting VE/VM is the necessity, and the scope must expand from research to sales and services.