1. Information Phase:

• Gathered all relevant data on the components, including existing design, material, manufacturing processes, and cost details.
• Analyzed production costs and conducted market research to benchmark against competitors.

2. Function Analysis Phase:

• Conducted a Function Cost-Worth analysis to determine the basic and secondary functions of each component.
• Identified high-cost areas that could be optimized without sacrificing essential functions.

3. Creative Phase:

• Engaged in brainstorming sessions with cross-functional teams to generate ideas for material substitutions, process improvements, and design optimizations.
• Explored various alternatives, including lightweight materials and modular design strategies.

4. Evaluation Phase:

• Assessed the feasibility of each creative idea using decision matrices, considering cost, performance, manufacturability, and supplier availability.
• Prioritized the ideas that offered the highest value improvement with the lowest risk.

5. Development Phase:

• Developed detailed CAD models of the optimized designs, ensuring that the new designs met both cost and performance criteria.
• Performed Finite Element Analysis (FEA) to validate the structural integrity and performance of the proposed changes.
• Collaborated with suppliers to confirm the feasibility of alternative manufacturing processes and material choices.

6. Implementation Phase:

• Released the final manufacturing drawings with the optimized designs, including any necessary changes to the production process.
• Coordinated with the client and suppliers for the smooth integration of new designs into the production line.
• Provided support during the prototype testing and validation stages to ensure the revised components met all required standards.