© Satyam Satyam | Integrated Engineering Solutions 1 Welcome to the court of Emperor Jalaluddin Muhammad Akbar

© Satyam Satyam | Integrated Engineering Solutions 2 Noble men! There is a very important matter before the court today. The raw material price is shooting up. The material cost of a sword has gone up by Rs.10. And …. We are adding 50,000 soldiers to our army this year. I want to handle this situation without increasing the taxes. Please give your valuable suggestions as to how we should face this situation.

© Satyam Satyam | Integrated Engineering Solutions 3 !? !! ?? Why everyone’s quiet? Birbal! I am surprised that you too have become silent!! Why everyone’s quiet? Birbal! I am surprised that you too have become silent!! Your Majesty, I have six ideas which can reduce the cost of a sword by atleast Rs.20 without compromising the functional requirements. Brilliant!. Tell us those ideas. Brilliant!. Tell us those ideas.

© Satyam Satyam | Integrated Engineering Solutions 4 Presently, the hilt has 7 parts. The proposed design will have 4. Existing Design 7 parts New Idea 4 parts Part Count Reduction

© Satyam Satyam | Integrated Engineering Solutions 5 For the new hilt, instead of designing exclusive rivets, we can use the rivets of daggers. For the new hilt, instead of designing exclusive rivets, we can use the rivets of daggers. Part Commonisatio n x

© Satyam Satyam | Integrated Engineering Solutions 6 When the Shah of Persia was our Guest last month, I observed that the hilt in his sword does not have a curved portion. We can design similar hilts for our experienced soldiers. When the Shah of Persia was our Guest last month, I observed that the hilt in his sword does not have a curved portion. We can design similar hilts for our experienced soldiers. Benchmarking New Idea Existing Design Curved portion

© Satyam Satyam | Integrated Engineering Solutions 7 Alternate Material Blade Sheath Copper Steel The sheath which houses the blade is made of copper now. We can switch over to Alloy steel which is cheaper. The sheath which houses the blade is made of copper now. We can switch over to Alloy steel which is cheaper.

© Satyam Satyam | Integrated Engineering Solutions 8 Weight Reduction Blade Sheath Since alloy steel is stronger than copper, we can reduce the thickness by 0.5 mm which will save material 2 mm 1.5 mm

© Satyam Satyam | Integrated Engineering Solutions 9 Yield Improvement The curved blade design is yielding only 2 pieces per die. If a straight blade is designed, we can extract 3 pieces per die. 2 Blades 3 Blades

© Satyam Satyam | Integrated Engineering Solutions 10 Your majesty. The present design is being used since the time of Babur without any failure. We should not risk any design change. Your majesty. The present design is being used since the time of Babur without any failure. We should not risk any design change. Saheb, there is no doubt that the present sword designed by you for my Grandfather’s army is superior. However, let us test this new design in our barracks.If they pass the tests, we will deploy them in the battle field. If the ideas pass the test, we can save atleast Rs. Ten Lakhs this year, thus serving the purpose of cost reduction. There is an advantage also. I do not have to increase the tax.

© Satyam Satyam | Integrated Engineering Solutions 11 Birbal! I wonder how you developed these ideas! Is there a systematic way by which others can also be trained to generate such ideas. Yes, your Majesty. With the help of Functional Analysis System Technique(FAST) any body can generate such ideas. FAST is a powerful tool used in Value Engineering (VE) which is an extremely effective system to improve products and services for cost and productivity improvement. Yes, your Majesty. With the help of Functional Analysis System Technique(FAST) any body can generate such ideas. FAST is a powerful tool used in Value Engineering (VE) which is an extremely effective system to improve products and services for cost and productivity improvement. If six ideas for the sword itself can save Rs. Ten lakhs, imagine how much money we can save on other weapons like spears, arrows and cannons etc. If six ideas for the sword itself can save Rs. Ten lakhs, imagine how much money we can save on other weapons like spears, arrows and cannons etc.

© Satyam Satyam | Integrated Engineering Solutions 12 Birbal! There are four divisions in my army – Infantry, Cavalry,Artillery and Elephant brigade. I want you to teach the engineers in each of these divisions the application of Value Engineering (VE), especially the Functional Analysis System Technique(FAST). Each division should release Armoury Change Requests (ACRs) for the worth of Rs.25 lakh. Yes, your Majesty.

© Satyam Satyam | Integrated Engineering Solutions With regards, Raamkumar Thiyagarajan, Design - Shipbuilding, Larsen and Toubro Limited.