Integration of Design for X (DfX) and Value Engineering (VE) Methods for Product Redesign to Improve Productivity (Case study: L-Series production at PT. XYZ)

Abstract

The increasingly intense global competition in the manufacturing sector has compelled companies to continuously improve productivity through the optimization of product design and production processes. The L-Series design manufactured by PT. XYZ exhibits inefficiencies and ineffectiveness, particularly in the design of the connection support and bottom sheet. The existing design requires complex manufacturing and assembly processes, resulting in high production costs and potential safety hazards for operators. To address these challenges, this study proposes a product redesign approach by integrating Design for X (DfX) principles, comprising Design for Manufacturing (DfM), Design for Assembly (DfA), and Design for Safety (DfS), with Value Engineering (VE). The redesign of the connection support and bottom sheet reduces the average production time by 22.96 minutes per unit and provides a potential production cost saving of IDR 16,834,120.03 per month. Furthermore, the proposed redesign eliminates the potential hazards associated with the welding process and prevents the previously identified risk of hand-crushing accidents during the manufacturing and assembly processes. These results demonstrate that the integrated DfX–VE approach can effectively improve manufacturing efficiency, reduce production costs, and enhance operator safety while maintaining the functional requirements of the product.