chapter 19

Problems for Assignment

In order to help the reader supplement his acquisition of value analysis

knowledge a number of problems from actual practice are offered in the
following "do-it-yourself" exercises. It should be noted that these prob-
lems are all limited to individual parts or components rather than to
inclusive assemblies. This is intentional because students can hardly be
expected to devote as much time to problem solving as exercises on a
series of complete products would require.

19-1 Procedure for Using the Problems

1. Make your plan for the problem.
2. Follow through each of the steps of the job plan.
3. Fill in some typical information that you have learned or have de-
veloped in each phase of the plan.
4. Fill in some typical information that you might learn or have de-
veloped by using each of the techniques.
5. Arrive at one or two suggested value alternatives that you believe
may be quite good.
6. Prepare an appropriate suggestion sheet.
 Problems for Assignment 331

There are no "pat" solutions to these problems; however, one answer

for each problem which met the need at the time is included in the
Appendix. Do not necessarily duplicate the part, but achieve the desired
function more economically.

19-2 Problems

1 . Special brass nut. Double thread, '/z inch square; made on

automatic screw machine; 1 million per year; 3 cents each.
Nut receives hand adjustment screw on electic blanket thermo-
stat.
Fig. 19-1

2. Steel control shaft. 1/4 inch in diameter, 11/4 inches

long; made on automatic screw machine; 1 million per
year; 6 cents each. One end screws into brass nut above,
other end mounts plastic knob. Center groove provides
adjustment for the thermostat.
Fig. 19-2

3. Stainless-steel fastening screw. 1%inches long; made

from %-inch diameter stainless steel on automatic screw
machine; contains shoulder and undercut section; 40,000
per year; 90 cents each. Used on panels of electronic
equipment.
Fig. 19-3

4. Handle. Made from %-inch aluminum; 4-inch centers;

threaded aluminum collars at each end form method of
mounting; 4,000 per year; $1.40,each. Used for convenient
handling of electronic equipment when it is out of master
panel.
Fig. 19-4
332 Techniques of Value Analysis and Engineering

5. Toggle link. 1% inches long; other dimensions in propor-

tion; made as steel forging with later machining; 25,000 per
year; 50 cents each. Used in electronic equipment mounted
in cabinet.
Fig. 19-5

6. Plastic coil f o r m . About 1 inch square by '/z inch

long; molded, then finish-machined; 15,000 per year;
40 cents each. Mounts coil in electronic control equip-
ment.

Fig. 19-6

7 . Control gear. Turned, machined, and hobbed from bar

steel; approximately 4 inches in diameter, % inch thick; hub '/2
inch thick; 600 per year; $8 each. Slow-speed gear used in
adjustment of electrical equipment; mounted inside enclosure.
Fig. 19-7

8. Hydraulic cylinder cap. Made from 3/8-inch-thick

steel; 3 inches square; 1-inch blind hole drilled '/4 inch
deep in center and four small mounting holes drilled in
corners; 2,000 per year; 53 cents each. Used inside
machine.
Fig. 19-8

9 . Adjustment screw. 1/4 inch in diameter; made from brass bar

by automatic screw machine; 200,000 per year; 1 cent each. Used
in electronic control equipment.
Fig. 19-9
 Problems for Assignment 333

10. Brass terminal clamp. Made by fabrication from brass

extrusion, approximately '/2 inch long, '/4 inch wide, inch
high; is mechanical part that does not conduct current; 400,000
per year; 7 cents each. Used inside electrical control box.
Fig. 19-10

11. Strain bolt assembly. 1 foot long; consists

of machined iron casting threaded with suitable
- bushings and nuts; made of steel; 5,000 per
year; $3.50 each. Used out of doors to support
Fig. 19-11 wires and cables.

12. Counterweight balance. Steel; cut from ring

of %-inch steel, 1 inch across; each segment
mounts on two studs; pieces approximately 3 inches
long; 5,000 per year; 40 cents each. Mounts on
large ring for counterbalance purposes.
Fig. 19-12

13. Fan. 15 inches in diameter; cast and machined from

malleable iron; punched steel ring riveted to one side of
blades; blade about 2 inches thick, hub about 3 inches thick;
1,600 per year; $17 each. Used for cooling air inside large
electric motor.
Fig. 19-13

14. Small crankshaft for air compressor. 7 inches long

for two connecting rods; forged and machined; 9,000 per
year; $5 each.
Fig. 19-14

15. Brass heater plug. Machined from hex bar 1%

inches across flats; approximately '/2 inch thick; 10,000
per year; 80 cents each. Mounts Calrod heaters into
furnace equipment.
Fig. 19-15
334 Techniques o f Value Analysis and Engineering

16. Fan-blade assembly. Approximately 1 x 2-foot

composite of three pieces of metal and one of plastic;
3,000 per year; $7 each. Function is to clamp on large
revolving ring in electric generator and deflect air.
Fig. 19-16

17. Steel pulley. Machined from 6-inch steel rod; 150 per
year; $30 each. Used on machines in factory.
Fig. 19-17

18. Plastic nut. Machined from 1/2-inch-thick plastic sheet;

1% inches square, %-inch hole drilled and tapped; 25,000
per year; 13 cents each. Used in electrical equipment.
Fig. 19-18

19. Bronze arcing horn. 15 inches

long by 2 inches wide; fabricated from
formed sheet brass by brazing; other
dimensions approximately as illustrated;
3,000 per year; $6.50 each. Function is
Fig. 19-19 to cool an arc so it will extinguish.

20. Cover fastener. Steel, 4-inch shank mounted in steel

U strap; 4,000 per year; 45 cents each. Function is to
secure cover on industrial equipment.
Fig. 19-20
 Problems for Assignment 335

21. Insert for coil-making machine. Ma-

chined from steel block about 3 inches long by
234 inches wide by 2 inches deep; 500 per year;
$80 each.

Fig. 19-21

22. Tapped resistor assembly. Made in fac-

tory assembly department; 300 per year; $7.50
each. Used in electrical instrument.

Fig. 19-22

23. Porcelain cap. 3-inch inside diameter, 2-inch inside height;

150,000 per year; 40 cents each. For weather protection, outdoor
switch gear.
Fig. 19-23

24. Stud pin. Galvanized-steel screw with stainless-

steel insert pin; over-all length, 3 inches; 50,000 per
year; 25 cents each. For outdoor use on electrical
equipment.

Fig. 19-24
336 Techniques of Value Analysis and Engineering

25. Flange. Made from steel bar by machining and turning

flange, drilling and tapping two mounting holes; 1,500 per
year; $1 each. Function is to hold a Calrod heater loosely
through a 2-inch diameter hole in the side of an electric
furnace.
Fig. 19-25