フナックス・エンジニアリング List of Products and Services

This is a course aimed at enhancing cost-effective design capabilities by developing component information settings (1. Material 2. Processing steps 3. Required specifications 4. Issues) based on VA/VE perspectives. On May 20, 2020 (Wednesday), we will hold a full-day seminar on the above topic, hosted by the Nikkan Kogyo Shimbun. Please check the "News" section for details.

• Technical Seminar

■Introduction of methods for quality optimization based on specifications, enabling cost reduction through a review of optimal shapes. ■Improving quality, delivery time, and price is also important to tackle through case studies! The first step begins from this site. ■What is necessary when setting tolerances to reduce defect rates? There are various methods to mitigate defect rates. This image is one of them. However, it is important to note that this method may lead to increased costs. Key Point: Setting tolerances optimized for processing is crucial. ■Original design pursuing ease of integration, improvement measures focusing on processability. Original type: The bearing is supported at the shoulder part that narrows from the center of the shaft. ■Improved type: The shaft is made straight, and the bearing is supported at the holder side. Key Point: It is important to choose shapes with low processing costs. ■As an issue: As a result of clarifying the causes of frequent defects, advice was given that establishing a step on the shaft for assembly would reduce defects more than determining the tolerances for the bearing support part from the holder side of the processor, leading to this shape.

• 3D CAD

The VA and VE approach methods are explained as follows: ■ Knowledge to know before starting VA and VE for the first time ■ Transition from 2D diagrams to 3D diagrams ■ Basic attitude for successful cost reduction Thorough organization of people, materials, money, time, and information Thorough implementation of 5S: Seiri (Sort), Seiton (Set in order), Seiso (Shine), Seiketsu (Standardize), Shitsuke (Sustain) P-D-C-A: Planning and execution, budget and actual results (comparison of budget vs. actual) ■ Explanation of the meaning of VA and VE ■ What is VEC? Value Engineering for Customers ■ Meaning of teardown and specific applications ■ Explanation of the approach to VA and VE (relationship with the principle of learning from the past and super recovery, etc.) ■ Relationship between VA, VE, and the principle of super recovery What is the principle of super recovery? ■ Definition of parts that can implement VA and VE ■ Strategies for tackling VA and VE From materials From changes in processing methods From changes in processes From changes in shape Weight reduction Reduction of parts Strategies through six types of applications mentioned above ■ Overview of VA and VE methods for cost reduction Here, you can download a PowerPoint-style presentation in PDF format.

• 3D CAD

One of the highlights of cost-reduction design through VA and VE is the optimization of processing methods, which I will introduce here. In VA and VE from MC processing to sheet metal processing, bending processes are incorporated to address areas lacking rigidity. The theme is MC processing → sheet metal conversion 1 (reducing the number of parts & reducing man-hours). As an initiative, we are addressing cost reduction by transitioning from MC plate processing to a sheet metal bending structure. We are considering reducing parts by using MC plate processing for the holding section of square pipes to enhance strength, while maintaining strength with a sheet metal bending structure. VA and VE content: We aim to increase strength with a bending structure and rib structure while also reducing parts by eliminating the intermediate plate. You can download a PowerPoint-style PDF on the catalog page.

• 3D CAD

The parts for mounting the attached box are designed for cost reduction using the simple is best approach of VA and VE. This is an introduction to cost reduction methods that can be achieved through optimal design, considering the weight of the mounting box and the frequency of removal. ■ From complex shapes to simple designs that can securely hold the box We aim to securely hold the box with a simple design without complicating the necessary shape, while also achieving cost reduction. ■ VA and VE content: Since the material costs increase when the shape is tailored to the size of the box to be held, we will aim for a design that can hold the box with a segmented shape. ■ Points to note: Create a layout diagram to check the shape of the materials. We will consider confirming the necessary parts and the areas that can be cut out to improve unnecessary shapes. ■ Considerations: Think about the necessary shapes for holding the main body and consider the minimum shape and the shape that needs to be held. You can download a PowerPoint-style PDF on the catalog page.

• 3D CAD

Avoid cost increases by integrating parts that arise from specification additions. They are currently separated and fastened with screws. We will consider methods to reduce costs by integrating them. ■ Key Point: Since adding parts leads to cost increases, we will design with additional processing in mind to find a solution. ■ Solving the increase in parts due to specification additions through integration: There is the integration of additional parts in processes skilled in sheet metal processing. Some issues can be resolved through notching and bending. ■ Key Point: To prevent cost increases from additional parts, especially small components, integration is highly recommended. The methods are introduced in a PowerPoint-style PDF on the catalog page.

• 3D CAD

The number of screws is proportional to the assembly labor, and this is a method to achieve cost reduction by tackling this aspect. Even with a small production lot, there are benefits from repeat production and using multiple parts per unit. ■ There are assembly tools for both rivets and screws. Assembly with rivets may seem similar to screwing, but the difference lies in the fact that rivets are set in one go, while screws require multiple turns for assembly, resulting in a time difference. ■ Method using claw tightening: The assembly is completed at the point of alignment and incorporation. When two parts are aligned and screwed together, or when rivets are aligned, the alignment and incorporation by claws are completed at that point, which means that the subsequent time for screwing or riveting is eliminated, leading to significant time savings. ■ The key point is to design claw stops of the same shape when there are multiple uses of the same shape or equivalent parts.

• 3D CAD

1. A cost-reduction design method using VA/VE to integrate multiple identical-shaped component units. 2. The advantage of integration over segmentation lies in the reduction of processing and assembly man-hours! As mentioned above, this is an introduction to the sheet metal processing VA/VE method that can reduce processing and assembly man-hours through component reduction. The key point is to achieve integration in a way that reduces processing and assembly man-hours when performing VA/VE on shapes. VA/VE content: By synthesizing multiple units of the same shape into one, significant reductions in man-hours and components can be achieved, leading to cost reduction. With this perspective, cost reduction can be realized.

• 3D CAD

A case where the difficulty of welding round pipes together can be addressed by reducing parts and eliminating welding processes through VA and VE, resulting in a cost-effective shape. The key point is to consider parts reduction in order to simplify end processing. Choosing square pipes to resolve the unstable welding of round pipes. When creating a link mechanism like this part with round pipes, a U-shaped component is welded at one point in the middle, and then the round pipes are attached to complete the assembly. This results in a three-point structure, which we will try to improve through VA.

• 3D CAD

By managing the dimensions of multiple similar products, it is possible to perform the dimensioning of identical shapes all at once, leading to cost reductions. Inventory management can also be streamlined by focusing only on the final shape, which can shorten delivery times. Adding "annotations" to the drawings for similar products has a significant impact on cost reduction. - Outer shape, length - Differences in processing positions - Same dimensions (e.g., variations in hole positions and dimensions) By writing these as "annotations" on a 2D drawing, it allows the processor to consider the optimal processing methods, leading to cost reductions.

• 3D CAD

This is a method to reduce costs by introducing units made of MC plate material. The theme involves significantly reducing processing man-hours while considering rigidity through cutting processes, starting from shape construction through machining. ■ This method is not suitable if precision in plate thickness is required through MC cutting. ■ Original part information: 2 pieces of SS material, reference dimensions: 10T×100×200, 2 units 6F processing + milling processing, holes, and screw processing ■ VA, VE content: Improvement of 2 pieces of plate material into sheet metal shapes. The reduction in thickness is addressed by incorporating bending processes to construct rigidity. If rigidity is insufficient, adding ribs can be effective. ■ Shape construction through cutting processes literally involves shaping by removing material, and the more material that is removed, the more processing man-hours are required. However, sheet metal processing constructs shapes through cutting, resulting in overwhelmingly fewer processing man-hours and significant cost reductions. ■ The issue is that the dimensional tolerances achievable through cutting processes differ from those in sheet metal processing, so specifications must be considered accordingly.

• 3D CAD

High-cost materials are reduced to only the necessary parts for cost savings! The cost is determined by assessing material costs and processing man-hours. At first glance, considering the shape of the material may seem to reduce processing man-hours and lead to total cost reduction, but high material costs can result in an overall increase in costs. Material costs are fixed expenses, but there is a significant possibility to adjust costs through processing methods like Value Analysis (VA) and Value Engineering (VE). In this case, we are conducting VA and VE to address the increase in man-hours resulting from the reduction of material costs. ■ Original Parts Information: Material Cost: SUS Material 1500×1500×50t Processing Details: Mounting holes for motors, indexers, etc., and screw hole processing. ■ VA, VE Details: SUS Material: Incorporation of channel and angle materials for a welded structure. Processing Details: Construction of the lower structure through welding; processing details remain the same. ■ The significant reduction in material costs is a major benefit, but total costs can vary based on processing details, so careful assessment is crucial. The explanation in PowerPoint format can be viewed in a 4-page PDF.

• 3D CAD

This is a cost reduction example where special dimension representation methods, shape representation methods, and other display methods in 2D drawings are designed from the perspective of the processor. When dimension indications that are not commonly used are supplemented with explanations, it leads to cost reductions and makes it easier for the processor. ■Original Information: In this case, the use of the "exponential curve," which is not commonly seen, leads to a situation where the processing instructions are not well understood at the processing site, resulting in wasted time before the actual processing begins, ultimately causing an increase in labor costs. ■VA, VE Content: In this case, while designers may think that writing the definition of the curve will help processors understand, in reality, it is quicker for processors to create a dimension table with the X and Y coordinates of points and connect them with a curve. Displaying this point on the drawing results in a total reduction in labor costs. Currently, with the advanced numerical control of machine tools, I believe that effectively utilizing this point can lead to high-quality finishes.

• 3D CAD

The shape that emphasizes strength and rigidity poses a problem in terms of weight, and simply machining it will lead to a significant increase in processing time and costs. Making the part in a square pipe shape, as in this case, is optimal for weight reduction, but the increase in processing time becomes an issue. ■ As a ONE POINT consideration, we took into account both material optimization and shape optimization for weight reduction through machining. ■ Original part information: Material: SS material, 60×70×150 square pipe shape with a thickness of 10t. ■ VA, VE content: Material: SS material → A5052S Weight reduction measures: By adopting a milling process with a depth of 10 from the square pipe shape, we achieved a significant reduction in processing time through the selection of materials that consider the reduction of cutting volume and machinability, leading to cost reduction.

• Mechanical Design

Introduction to the Benefits of Standardizing Sheet Metal Materials When selecting sheet metal materials, it is standard practice to consider strength and design with the necessary thicknesses. For mass production, it is possible to produce quantities that fully utilize standard sheets of 3×6 or 5×10. However, in small-scale production, every time parts with different thicknesses are processed, it is necessary to switch between a turret punch press and a laser cutting machine. This results in labor for setup changes and managing multiple materials. Although it is not visible, it can be quite cumbersome. The key point is to incorporate bending structures in VA and VE for stable strength when standardizing thickness. For strength enhancement, the ability to construct shapes according to specifications through bending on one side, two sides, three sides, four sides, and even into a U-shape is the essence of VA and VE.

• 3D CAD

Lightweighting and reducing processing steps of SS material block-shaped units through sheet metal fabrication. By maintaining rigidity with machining while converting unnecessary parts to sheet metal, we can reduce the number of components and processing steps, significantly contributing to cost reduction. Here is a sample of that. ONE POINT: For precision parts, machining is used, and if the processing accuracy can be relaxed for associated parts, considering sheet metal can open the path to cost reduction. This unit is a sample of a slide unit machined using a common proximity switch. If high precision is required for such a unit, machining is optimal, but if slightly relaxed precision is acceptable, it is also possible to convert the receiving part that holds the rod to sheet metal, as shown in the image. Additionally, if strength is not required for the parts holding the proximity switch, it is believed that manufacturing them through sheet metal processing can significantly reduce processing steps.

• Machinery and equipment installation/dismantling/relocation

This is one method for cost-reduction design when using structural steel materials for canning processing frames and supports, maintaining strength through VA and VE based on specifications while preserving the same shape through sheet metal processing. The key point is to construct equivalent shapes to angles, channels, and square pipes through sheet metal bending processing. Canned structural enclosures are suitable for units that require rigidity, but when comparing with units made from equivalent shapes through sheet metal processing, the latter has advantages in terms of processing man-hours and precision. In the case of structural steel, the surface of the material is in a cast state, whereas sheet metal materials have a clean surface, providing advantages in terms of plating and painting finishes for sheet metal processing.

• 3D CAD

This case study collection includes examples of cost reduction through VA (Value Analysis) and VE (Value Engineering) conducted by Funax Engineering Co., Ltd. We introduce various cases, starting with "Cost reduction through checking whether equipment and parts match specifications." If you are interested, please feel free to contact us. [Contents] ■ The origin of VA and VE ■ VA and VE methods necessary for cost improvement ■ Explanation of the meaning of VA and VE, etc. *For more details, please refer to the catalog or feel free to contact us.

• 3D CAD

Funax Engineering Co., Ltd. specializes in machine design and component design focused on Value Analysis (VA) and Value Engineering (VE) to significantly reduce costs while maintaining the specifications required by our customers. In addition, we offer a wide range of services including contract machining, commercial website production, web design, and act as a total coordinator in precision equipment manufacturing, as well as providing technical consulting. For cost-reduction design through VA and VE, please feel free to contact us. 【Business Activities】 ■ Product Design ■ Cost Reduction Design ■ Improvement Design ■ Modification Design ■ CAD Conversion of Hand-Drawn Drawings, etc. *For more details, please refer to our catalog or feel free to contact us.

• Technology Development
• Other Consulting Services
• Other contract services

This is an example of how we were able to significantly reduce processing time, improve quality, and lower costs by dividing MC block parts with complex shapes that are difficult to machine into shapes that can be machined, using VA (Value Analysis) and VE (Value Engineering). Our company focuses on product design modifications through VA and VE, and improving products like this one from a monolithic structure to a split structure is one of the VA and VE methods we use to respond to our customers' requests for cost reduction. *For more details, please refer to the PDF document or feel free to contact us.

• Mechanical Design

Cost reduction through segmented processing of aluminum castings (a shift in thinking) [Before Improvement] ● Machining was done on aluminum castings (AC4C) ● The lot size was 3-5 pieces, with outer circumference processing and hole drilling ※ Considering the quantity, too much time was spent on setup, which reflected in the price [After Improvement] ● Stopped integration and separated each plate for machining ※ Eliminated the time spent on setup, resulting in significant cost reduction Collecting standard machined parts for casting usually leads to cost reduction. In the case of this component, the relationship between lot size and setup time negatively impacted costs, making it more expensive, so we deliberately chose the standard method. I believe this is also one idea. Additionally, by reverting to standard machining, we no longer needed to use specialized machinery, allowing us to shorten delivery times as well. ● Cost reduction effect: Existing product was 120,000 yen ↓ 60,000 yen (50% cost reduction) ■ Key Point: It is commonly understood that casting requires fewer processing steps, but when the production lot is small, setup time counts as processing time, so we are focusing on this aspect.

• Mechanical Design

A case of significant cost reduction achieved by integrating a split-type unit that gathers parts for grinding processing into MC cutting processing through VA and VE. The key point is to reduce processing man-hours significantly by transitioning from labor-intensive grinding processing to integrated MC cutting processing. VA, VE Information: Original Shape Material: SUS430 Key Material Shape Parts: 5×5×300, 16 pieces Key Material Receiving Blocks at Both Ends: 30×30×200, 2 pieces After VA, VE: Material: SUS430 The processing of 64 M2 screws (4 screws for each of the 16 key material shape parts) is prone to tap breakage defects. Improving this and finishing the key material shape through grinding processing requires a lot of man-hours. By switching to MC processing, this led to a significant reduction in processing man-hours, thus resulting in cost reduction.

• Mechanical Design

○Situation Before Improvement○ Material: SS400 Outer Diameter Shape: 140*200*180 【Before Improvement】 ●Due to the large number of machining processes required for the SS400 shape, it was difficult to reduce man-hours. ↓ 【After Improvement】 ●By changing the outer frame to a sheet metal shape and machining the movable parts, we were able to significantly reduce processing man-hours by minimizing the shape of the actual necessary movable parts and simplifying the design. ●Cost Reduction Effect: Existing product costs 300,000 yen ↓ Converted to a unit cost of 60,000 yen (80% cost reduction)

• Mechanical Design

The original cost reduction strategy involves converting to lost-wax casting and casting, and reducing the number of parts through the integration of multiple components is effective. This is an example of standard parts reduction and integration. The image shows three parts that are bolted and welded together to form an arm. This shape is acceptable for small lots or one-off items. However, when there is a need for a certain volume of repeated production, it becomes necessary to adopt a shape that considers cost reduction. ONE POINT: It is optimal to integrate multiple parts of different shapes while leaving unnecessary surfaces in their cast state without further processing.

• Mechanical Design

This is a case of VA/VE that aims to reduce costs in sheet metal processing by minimizing setup and optimizing shapes. The key point in the cost reduction method is to unify materials while maintaining shape and reducing setup time to decrease man-hours. Sheet metal processing → Setup reduction (cost reduction through material reduction) To hold the central square pipe, it is structured with ribs on both sides. In such cases, adopting the same square pipe as the one that is standing up allows for material unification, which I think results in a fairly good shape. Here, one VA/VE has already been achieved, but we will further pursue cost reduction.

• Mechanical Design

The amount of cutting affects costs in proportion to the processing man-hours. By changing difficult-to-cut material parts to optimal materials based on specifications, we can reduce costs. The key is to identify parts that can be replaced with materials like aluminum and resin, which have lower cutting resistance. When considering the issues with SS and SUS material parts, we will think about possible solutions based on their poor machinability. There are cases where strength and rigidity are required from the parts, and there are also many instances where they are not required. In such cases, changing the material while keeping the same shape can open up avenues for cost reduction. We will consider solutions to this problem using Value Analysis (VA) and Value Engineering (VE).

• Mechanical Design

There are often causes for parts that frequently fail, and by making these issues apparent and resolving them, it often leads to cost reductions. "Not producing defects" is a hidden method for cost reduction. In this part, there are frequent occurrences of cracking at the marked circular area, leading to defects, so we will investigate the causes and seek countermeasures. ■Examining the current issues We will consider where the cause of the cracking lies. It is believed that the sharp angles at the marked area and the extreme narrowness of the left side compared to other surfaces make it prone to distortion due to temperature changes during hardening, resulting in cracking. 【Before Improvement】 ●Material: SK3, Heat Treatment: 55 degrees HRC The corners were finished at 90 degrees, causing stress during hardening and leading to frequent cracking. 【After Improvement】 ●Successfully eliminated defects from cracking by dispersing the stress during hardening.

• Mechanical Design