Aplicatiile Analizei Valorii-2-Optimizarea Lagarelor Amestecatoarelor-Autori: Florin Chichernea &...

8/9/2019 Aplicatiile Analizei Valorii-2-Optimizarea Lagarelor Amestecatoarelor-Autori: Florin Chichernea & Alexandru Chichernea

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IMPLEMENTING VALUE ANALYSIS IN DESIGNING OF MIXERS

FOUNDRY

Prof.univ.dr.ing. CHICHERNEA FLORIN1

Student CHICHERNEA ALEXANDRU1

1Transilvania University of Brasov, Brasov, Romania, [email protected]

ABSTRACT: Implementation of Value Analysis in

designing of industrial equipment is a demonstrated need

for a long time in highly developed industries. Beneficial

results of applying this creative, functional and verypractical multidisciplinary approach can see at all the

products that surround us in everyday life.

The paper presents a complete study of Value Analysis

applied concretely to a selected part of equipment. The

phases and iterative operation of the Value Analysis

method are presented. Value Analysis combines both

engineering and economics without, however, placing

neither engineering or economics first. They both are

similarly important, as can be concluded by the end of thispaper. Value Analysis (VA) is a method that provides an

operating technique using a creative and organizedapproach.

Keywords: value analysis, optimum variant, pillow block
mailto:[email protected]:[email protected]


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VALUE ANALYSIS APPLIED TO THE DESIGN OF A MIXER FOR MOULDING AND

CORE SAND PREPARATION

Value Analysis (VA) is a method that provides an operating technique using a crative and

organized approach.

It is managed by a group, each of them selected by their expertise in specific subjects and

coordinated by a Value Analysis expert.

The VA group activity is managed in seven stages:

- information and functional analysis, - creativeness, - evaluation and selection of the proposals, -

the creative phase, - development of the selected proposals, - presentation of the selected proposals,

set in order by priority, - implementation phase.An example of Value Analysis is presented, applied to the redesign of a mixer for moulding sand

preparation.

Next the establishing mode of the optimum constructive solution is presented from the technical and

economic viewpoint for a part participating in a function of over-dimensioned cost.

ESTABLISHING THE LIST OF TECHNICAL FUNCTIONS AND DIMENSIONS

Table 1 presents the list of functions of the mixer.


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Tab.2 Value weighting of the functions (* - X coordinate). Step 1Functions A B C D E F G H I J Total

A 1 0 0 0 0 0 0 0 0 0

B 1 1 0 0 0 0 0 0 0 0

C 1 1 1 0 0 0 0 0 0 0

D 1 1 1 1 0 0 0 0 0 0

E 1 1 1 1 1 0 0 0 0 0

F 1 1 1 1 1 1 0 0 0 0

G 1 1 1 1 1 1 1 0 0 0

H 1 1 1 1 1 1 1 1 0 0

I 1 1 1 1 1 1 1 1 1 0

J 1 1 1 1 1 1 1 1 1 1No. of points 10 9 8 7 6 5 4 3 2 1 55

Ratio 0,182 0,164 0,145 0,127 0,109 0,091 0,073 0,055 0,036 0,018 1

*Percentage % 18,2 16,4 14,5 12,7 10,9 9,09 7,27 5,45 3,64 1,82 100

The product value is equal to the sum of the functions levels and is equal to 55. The following

percentage values of the functions value weighting result: XA = 18,2 %, XB = 16,4 %, XC = 14,5 %,

XD = 12,7 %, XE = 10,9%, XF = 9,09 %, XG = 7,27 %, XH = 5,45 %, XI = 3,64 %, XJ = 1,82 %.

Figure 1 shows the studied mixer.


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Fig.1: Blade mixer: 1tank; 2blades; 3blade supports; 4shaft; 5electric motor;

6reducing gear; 7coupling; 8flute; 9pillow block; 12stopper; 13frame;

14protection grate.

ECONOMIC DIMENSIONING OF THE FUNCTIONS

Costs were assigned to the various functions by means of the functions costs matrix shown in

table 3.


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Tab.3 Distribution of costs on functions (*Y coordinate, ** monetary units). Step 1No. Parts Functions Cost

A B C D E F G H I J part**

1 Motor 100 85 25 60 55 5 3302 Reducing gear 150 150

3 Tank 20 15 50 70 30 28 10 25 248

4 Blades 150 50 200

5 Pillow Block 250 30 200 70 60 20 30 660

... ... 600 900 750 720 600 320 220 200 215 110 4635

Total cost 1270 1015 775 735 850 440 380 343 245 170 6223

Ratio 0,204 0,163 0,125 0,118 0,137 0,071 0,061 0,055 0,039 0,027 1

Cost of functions % 20,4 16,3 12,5 11,8 13,7 7,07 6,11 5,51 3,94 2,73 100The percentage values of the functions participation in the total cost are:

YA = 20,4 %, YB = 16,3 %, YC = 12,5 %, YD= 11,8 %, YE = 13,7 %, YF = 7,07 %, YG = 6,11 %, YH

= 5,51 %, YI = 3,94 %, YJ = 2,73 %.

DIAGRAMS

The construction of the diagrams is presented at last.

Based on the values for coordinates xi and yi presented in table 4 the diagrams of figures 2, 3, 4 and5 are plotted. The calculus is made with the smallest squares method.


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Tab.4 Computational elements for plotting the diagrams.*S'=2*a*(Xi)22*Xi*Yi. Step 1

No. Computational Functions Total

elements A B C D E F G H I J value

1 X i 18,2 16,4 14,5 12,7 10,9 9,09 7,27 5,45 3,64 1,82 100

2 Y i 20,4 16,3 12,5 11,8 13,7 7,07 6,11 5,51 3,94 2,73 100

3 (X i)2 330,6 267,8 211,6 162 119 82,64 52,89 29,75 13,22 3,306 1273

4 X i * Y i 371,1 266,9 181,1 150,3 149 64,28 44,41 30,06 14,31 4,967 1276

5 (Y i - a*Xi)2 4,722 0,01 4,556 0,909 7,387 4,191 1,410 0,001 0,084 0,825 24,1

6 S' * -79,0 3,314 62,09 24,27 -59,3 37,22 17,27 -0,44 -2,10 -3,30 0

The parameters have the following computed values: a = 1, 45,1o

, S = 24,1 and S'= 0.Table 4 provides the necessary values for constructing the following types of diagrams:

- Diagram of the value weighting of functions (fig.2),

- Diagram of the cost weighting of functions (fig.3),

- Diagram of the value and cost weighting of functions (fig.4),

- Diagram comparing the values and costs weighting of functions (fig.5).

Figure 2 shows the ranking of the functions by their value.

Figure 3 shows the ranking of the functions by their functional cost.

The diagram allows significant comparisons of the functions total costs, and within the total costs,

of the work and material costs:

- The very expensive functions with the highest weighting in the total cost of the product,
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- The secondary functions that are very expensive in relation to the objective functions, or even

more expensive than these,

The diagram reveals a Pareto type distribution, meaning that 20 - 30% of the total number of

functions, include 70 - 80% of the total costs of the functions. These functions are A, B and E.

In the case of such a distribution, the first functions in the order of costs, representing 20 - 30% ofthe total number of functions (in the above example functions A, B and E) are considered to be very

expensive functions.

The real situation is represented by the shape of the straight line in figure 4, plotted by means of the

smallest squares method, and showing disproportions in the distribution of costs and in the

contribution of the various functions to the value of the product.

An analysis of the diagram of figure 4 shows that functions I, E and I are located above the

regression line, indicating high costs, not justifiable in relation to the value.The disproportions are highlighted also in the diagram of figure 5, where it can be noticed that

functions I, E and A have disproportionate costs (3,94%, 13,66%, 20,41%) in relation to their

respective contributions to value (3,64%, 10,91%, 20,41%).

These aspects allow the assumption that these functions are deficient, hence the solutions to be

identified are to focus on those assemblies, parts, materials and technological operations that

contribute, within the general structure of the product, to the achievement of these functions.


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Fig.2: Diagram of the value weighting of

functions. Step 1

Fig.3: Diagram of the cost weighting of

functions. Step 1-


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Fig.4: Value and cost weightings of functions.

Step 1 Fig.5: Comparison of values weighting (x---) andcosts weighting of functions (y- - -). Step 1EVALUATION BY THE ECONOMIC DIMENSION CRITERION

The economic dimension or the cost of the function represents the main criterion for the critical

evaluation of functions.


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These evaluating aim at identifying those functions, the too costly technical solutions of

achievement of which affect the total manufacturing cost of the analyzed product. A correctly

completed critical evaluation will directly lead to the identification of what can be called the

deficient functions of the analyzed product, that is of those functions that include useless costs.

The deficient functions from the economic viewpoint appear as:- very expensive functions in relation to the others,

- too expensive functions in relation to the existing technical possibilities of achievement.

Evaluation by the criterion of economic dimension can be achieved in several ways, presented

below:

1) - comparison of costs per function, by means of the diagram presented in figure 3. This diagram

allows comparisons of:

- the costs of the functions and comparisons of the total cost and the cost of each function,- work and material costs, highlighting the very expensive costs, with the highest weighting in

the total cost of the product,

- functions the achievement of which requires disproportionate costs, of either work or material,

2) - comparison to the functions of other products. Other products refer to:

- products of the same typo-dimensional range or family, manufactured by that company,

- products similar to the analyzed one, manufactured by other companies,

- products with other destinations, but having some functions similar to those of the analyzed

product.The aim is to identify potential too expensive functions in relation to the existing achieved technical

solutions, existing and tested in other products.


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It is recommended to relate to the simplest existing technical solutions, that ensure the achievement

of the respective functions at minimum costs.

3) - theoretical evaluation of the costs of the function. Such an evaluation is possible when a

function is determined by a single part or by a small number of parts. Evaluation is carried out in

relation to material consumption. Based on the conclusions resulting from the critical evaluation ofthe functions, the study of the solutions will focus on identifying re-conception solutions of the

product, in view of reducing its costs and improving its value.

This is possible by constructive and technological modifications of the parts, sub-assemblies and

assemblies, according to the identified deficient functions.

ESTABLISHING THE FUNCTIONAL-TECHNOLOGICAL FORM OF THE PARTS IN

VIEW OF COST REDUCTION

An analysis from the technical and economic viewpoint will be carried out in order to select a

technically optimum variant for one of the parts: the Pillow Block. Five constructive variants of

Pillow Blocks will be studied and eventually the most cost effective and the most competitive one

from the technical and economic viewpoint will selected.


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Fig. 6: Welded Pillow Block

Prior to the actual study a number of basic ideas of creative engineering will be presented in short.

The figures 6, ..., 9 presents four variants of welded Pillow Block, the figures 10, ..., 17 presents

eight variants of Cast Pillow Block, and the figures 18 and 19 presents two variants of screw

assembled Pillow Block.


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Fig. 10: Cast Pillow Block


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Fig. 12 : Cast Pillow Block



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www.vxb.com/page/bearings/PROD/Kit7583

Fig. 16: Cast pillow block bearing, also known

as a plummer block
http://www.vxb.com/page/bearings/PROD/Kit7583http://www.vxb.com/page/bearings/PROD/Kit7583


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-

Fig. 17: Cast Pillow Block.www.spaug.org/3D_Models_Index99.Html
http://www.spaug.org/3D_Models_Index99.Htmlhttp://www.spaug.org/3D_Models_Index99.Html


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Fig. 18: Screw assembled Pillow Block

Fig. 19: Screw assembled Pillow Block


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THE ANALYSIS OF THE CONSTRUCTIVE VARIANTS

The analysis of the constructive variants for the Pillow Block of figures 6, ..., 19 is presented on.

An analysis from the technical and economic viewpoint will be carried out in order to select a

technically optimum variant of Pillow Block. Three types of variants (welded, cast and screwsassembled) will be studied in the fallowing, in terms of engineering and the most cost effective and

the most competitive one from the technical and economic viewpoint will selected.

The type of cast Pillow Block obtained from a cast semi-product ensures the best functional

characteristics, if the technical conditions for heat treatment are provided. It has, however, the

disadvantage that it allows only one solution for reconditioning: build-up welding and re-machining

to the initial functional dimensions.

Table 5 presents the denoting by 9 assessment criteria of the analyzed constructive variants of

Pillow Block.


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Tab.5 Synthetic table with the analyzed constructive variants

No. Analysis criteria Type of Pillow Block

welded cast screw assembled

variant initial final

1 Functional characteristics 6 6 62 Semi-product 2 6 5

3 Mechanical machining 4 6 5

4 Mounting 4 5 4

5 Repair 3 4 6

6 Rigidity 4 5 4

7 Ergonomics 6 6 6

8 Aesthetics 6 6 69 Cost 2 4 3

TOTAL 37 48 45

But in many cases the Pillow Block must be made of two parts, to facilitate quick installation and

removal of all assembly (figure 18 and figure 19). The bottom can body with the cradle, can be

incorporated into the cradle.

Type of cast variant obtained a score better than the welded variant and screw assembled Pillow

Block variant, but in many cases the Pillow Block must be made of two parts, to facilitate quick

installation and removal of the assembly.


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The score obtained by the screw assembled Pillow Block variant is less than the cast Pillow Block

variant, but choose the screw assembled Pillow Block variant (figure 19), because the weight of the

advantages for the screw assembled Pillow Block is greater than the weight of disadvantages for the

cast Pillow Block variant.

The screw assembled Pillow Block variant has the following advantages over the cast Pillow Blockvariant:

1. installation and removal are all much easier,2. maintenance runs also easier,The disadvantages of the screw assembled Pillow Block variant to the cast Pillow Block variant are:

1. the process of obtaining semi product: it can see in this choice the piece is composed of twomodules,

2. the machining by cutting: machining process is longer, more complicated and costly,3. the functional cost of this variant is greater, but the difference is non significant.The cost of the final variant of figure 19 (the screw assembled Pillow Block variant) presented in

table 6 (step 2 of the Value Analysis study) is of 580 monetary units and has a weighting of

11,4% of the final cost as compared to the initial situation of 660 monetary units with a weighting

of 13,66% presented in table 3 (step 1 of the Value Analysis study).


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Tab.6 Cost distribution on functions (partial). (*Y coordinate, ** monetary units)

No. Parts Functions Cost

A B C D E F G H I J part**

1 Motor 100 85 25 60 55 5 330

2 Reducing gear 100 1003 Tank 20 15 50 70 30 28 10 25 248

4 Blades 150 50 200

5 Pillow Block 250 30 120 70 60 20 30 580

... ... 600 800 720 700 500 310 230 220 230 125 4435

Total cost 1220 915 745 715 670 430 390 363 260 185 5893

Ratio 0,207 0,155 0,126 0,121 0,114 0,073 0,066 0,062 0,044 0,031 1

Cost of functions % 20,7 15,5 12,6 12,1 11,4 7,3 6,62 6,16 4,41 3,14 100

The final situationstep 2 of the VA study

By introducing the new data into table 7 the diagrams of figures 20, 21 and 22 are plotted.

These diagrams will be compared to those of figures 2, 3 and 4.
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Tab.7 Computational elements for plotting the diagrams.* S' =2*a*(Xi)22*Xi*Yi

No. Computational Functions Total

elements A B C D E F G H I J value

1 X i 18,2 16,4 14,5 12,7 10,9 9,09 7,27 5,45 3,64 1,82 100

2 Y i 20,7 15,5 12,6 12,1 11,4 7,3 6,62 6,16 4,41 3,14 100

3 (X i)2 330,6 267,8 211,6 162 119 82,64

52,89

3

29,75

2

13,22

33,306

1272,

7

4 X i * Y i 376,4 254,1 183,9 154,4 124 66,33 48,13 33,59 16,04 5,708 1262

5 (Y i - a*Xi)2 7,101 0,5 3,197 0,243 0,299 2,965 0,356 0,560 0,647 1,784 17,65

6 S' * -96,9 23,14 52,02 12,56 -11,9 31,31 8,684 -8,16 -5,85 -4,85 0

Step 2

The parameters have the following computed values: a = 0,99, ,8 o, S = 17,65, S' = 0.

It can be noticed that S and S' have smaller values than in the initial variant.
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Fig. 20Diagram of the value weighting of

functions. Step 2

Fig. 21Diagram of the cost weighting of

functions. Step 2

Table 7 provides the necessary values for the plotting of the following types of diagrams:

- the diagram of the value weighting of the functions (figure 20 identical with figure 2); this

diagram has not changes, as the value of the system and of the functions has remained the same,
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- the diagram of the cost weighting of the functions (figure 21); the diagram of figure 21 presents

the functions cost weighting,

- the diagram of the value and cost weightings of the functions (figure 22); figure 22 presents the

value and cost weightings of the functions in step 2.

In this diagram is observed the decrease of the cost of function E, from 13,66 %, in first step ofValue Analysis study (fig.4) to 11,37 % in second step of Value Analysis study.
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Fig. 22Value and cost weightings of functions in step 1 and step 2
http://../4-Congr.ROMANIA/16-CURSURI/5-C%C4%83r%C5%A3i%20%C3%AEn%20Lucru/6-Estetica+Design/2-curs/Cap%2010-Studiu/11-Dia+Fig%20Tema%202-AV.xlshttp://../4-Congr.ROMANIA/16-CURSURI/5-C%C4%83r%C5%A3i%20%C3%AEn%20Lucru/6-Estetica+Design/2-curs/Cap%2010-Studiu/11-Dia+Fig%20Tema%202-AV.xlshttp://../4-Congr.ROMANIA/16-CURSURI/5-C%C4%83r%C5%A3i%20%C3%AEn%20Lucru/6-Estetica+Design/2-curs/Cap%2010-Studiu/11-Dia+Fig%20Tema%202-AV.xlshttp://../4-Congr.ROMANIA/16-CURSURI/5-C%C4%83r%C5%A3i%20%C3%AEn%20Lucru/6-Estetica+Design/2-curs/Cap%2010-Studiu/11-Dia+Fig%20Tema%202-AV.xlshttp://../4-Congr.ROMANIA/16-CURSURI/5-C%C4%83r%C5%A3i%20%C3%AEn%20Lucru/6-Estetica+Design/2-curs/Cap%2010-Studiu/11-Dia+Fig%20Tema%202-AV.xls


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At the moment, in the second step the calculation shall be made as fallows:,

- others functions can bee situated above the regression straight line,

- these are analyzed and their costs reduced, then the regression line is re-plotted and the

functions relocated above it are noted; these functions too are analyzed in view of reducing their

costs, followed by the re-plotting of the regression line, etc., etc.Hence the constructive solution is improved from one iteration to the other.

CONCLUSIONS

In two steps of Value Analysis study one component of mixer for moulding and core sand

preparation, the who contribute at the function E (supports the assembly), was redesign and

optimized:

1. from engineering viewpoint (figure 23): from variant of Pillow Block of figure 6 composed ofwelded modules, one complicated part (many components, mechanical machining, turning of metal

parts complicated, long and very expensive, etc.) to the variant of figure 19 composed of screw

assembled Pillow Block (two component, mechanical machining, turning of metal parts simple,

short and less expensive than the Pillow Block of figure 6, etc.).


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Fig. 23

2. from the economic viewpoint (figure 24): the cost of function E (figure 24) decrease from 13,66

%, in the first step of Value Analysis study to 11,37 % in the second step of Value Analysis study

(decrease with 20,1 %).


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Fig. 24

3 in the third step of Value Analysis study are analyzed other functions above the regression

straight line (for exemple I) and their costs reduced, then the regression line is re-plotted and the


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functions relocated above it are noted; these functions too are analyzed in view of reducing their

costs, followed by the re-plotting of the regression line, etc. etc.

4 in the third step of Value Analysis study are analyzed other functions above the regression

straight line and their costs reduced, then the regression line is re-plotted and the functions relocated

above it are noted; these functions too are analyzed in view of reducing their costs, followed by there-plotting of the regression line, etc. etc.

At the end of the Value Analysis study the points are aligned as perfectly as possible along the

straight line y = a * x, with a tilt of 45o, this is the optimal situation, the values weighting of

functions and the functions cost weighting are equal, the final interest in Value Analysis study

REFERENCES

[1]. Chichernea, Fl.:Analiza Valorii , Editura Universitii Transilvania din Braov, 2002[2]. Chichernea, Fl.: Analiza valorii, ISBN (10) 973-635-850-X, ISBN (13) 978-635-850-0,Editura Universitii Transilvania Braov, 2007

[3]. Chichernea, Fl.:Analiza valorii , Universitatea Transilvania Braov, 2007, CD[4]. Chichernea, Fl.: Analiza Valorii. Partea I, Bramat 2007, Proceedings InternationalConference on Materials Science and Engineering, Braov, Romnia, 22-24.feb.2007, vol.I, ISSN

1223-9631,[5]. Chichernea, Fl.: Analiza Valorii. Partea II, Bramat 2007, Proceedings InternationalConference on Materials Science and Engineering, Braov, Romnia, 22-24.feb.2007, vol.I, ISSN

1223-9631,


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[6]. Chichernea, Fl.: Analiza Valorii diagrame FAST. Partea IV , Revista Metalurgia, nr.5,2005, pg.30

[7]. Chichernea, Fl.: Analiza Valorii n industrie, Editura Universitii Transilvania din Braov,2008, ISBN 978973 5982089

[8]. Chichernea Fl.: Value analysis, Parth I. Rev. Metalurgia International, nr.9, 2008, pg. 62,ISSN -1582-2214.[9]. Chichernea Fl.: Value Analysis, parth II, Rev.Metalurgia International, nr.3, 2009, pg. 5,ISSN -1582-2214.

[10]. Chichernea Fl., Chichernea Al.: Value Analysis, parth III, Rev.Metalurgia International, nr.2,2010, pg. 22, ISSN -1582-2214.

[11]. Chichernea Fl., Chichernea Al.: Value Analysis, parth IV, Rev.Metalurgia International, nr.3,2010, pg. 20, ISSN -1582-2214.

[12]. Chichernea Fl., Chichernea Al.: Value Analysis as an Iterative process InternationalScientific Conference Management of Technology Step to Sustainable production MOTSP

2009, 1012 june 2009, Sibenik, Croatia, Conference, Proceedings, University of Zagreb, Faculty

of Mechanical Engineering and Naval Arhitecture, University of Primorska, Faculty of

Management Koper, pg. 39, ISBN 978-953-6313-09-9

[13]. Chichernea Fl., Chichernea Al.: Value Analysis one iterative methode for design Parth I,14th International Conference Theoretical and Experimental Problems of Materials Engineering

Progress in Materials Engineering, Ostravice, Czesh Republic, 24 27 August 2009, pg 71.Publicat n vol.3, rocnik LII, Transactions of the VSB Technical University of Ostrava,

Metallurgical Series, ISBN 978-80-248-2039-2, ISSN 0474-8484


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[14]. Chichernea Fl., Chichernea Al.: Value Analysis one iterative methode for design Parth II14th International Conference Theoretical and Experimental Problems of Materials Engineering

Progress in Materials Engineering, Ostravice, Czesh Republic, 24 27 August 2009, pg 79.

Publicat n vol.3, rocnik LII, Transactions of the VSB Technical University of Ostrava,

Metallurgical Series, ISBN 978-80-248-2039-2, ISSN 0474-8484[15]. www.spaug.org/3D_Models_Index99.Html
http://www.spaug.org/3D_Models_Index99.Htmlhttp://www.spaug.org/3D_Models_Index99.Html

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