20

CHAPTER 3

INVESTIGATION ON IMPROVISING THE SIX ROW

MANUALLY OPERATED PADDY TRANSPLANTER THROUGH
THE APPLICATION OF VALUE ENGINEERING JOB PLAN

3.1 INTRODUCTION

Researchers and manufacturers have been developing devices and

machineries to enhance the easiness of carrying out various farming activities
like land preparation, sowing, transplanting, planting, harvesting, threshing and
post-harvest processing. Among all developing machineries for transplanting by
plants like paddy seedlings has been posing several challenges to the engineers.
Paddy transplanter is one of the equipment for transplanting the paddy seedling
on wet field at rice farming area. This is due to the reason that transplanting
machineries are required to be developed for performing under several soil
conditions. Researchers and manufactures have developed paddy transplanters.
These paddy transplanters are highly expensive. Moreover, in order to operate
these semi-automatic paddy transplanters, complex steps are to be followed.
Hence, farmers with little earning and poor intelligence using these semi-
automated paddy transplanters are unable to use these paddy transplanters.
In order to overcome this deficient situation, while pursuing the doctoral work
reported in this thesis.

Two investigations on applying value engineering job plan for

improvising a paddy transplanter called ‘six row manually operated paddy
transplanter’ were carried out. One of these investigations is presented in this
chapter. While carrying out this investigation, a six row manually operated paddy
transplanter was improvised by applying value engineering job plan. The widely
followed procedure of value engineering job plan begins with the phase called
 21

orientation phase and ends with audit phase (Mukhopadhyaya 2010). The details
of executing these phases of value engineering job plan to improvise this product
are presented in this chapter.

3.2 ORIENTATION PHASE

Before beginning the orientation phase, it is required to form a value

engineering team (hereafter, referred to as team). The Society of American Value
Engineering (SAVE) recommends the conduct of orientation programme to the
value engineering team members (hereafter, referred to as team members) before
stating a value engineering project (Mukhopadhyaya 2010). While conducting
the instigation being reported here, the farmers could not become team members
due to their illiteracy. Hence, instead of forming a team, the opinions and
experiences of using six row manually operated paddy transplanter were
gathered by having informal talks with farmers. While carrying out this exercise,
farmers expressed many technical difficulties experienced by them while using
six row manually operated paddy transplanter. Particularly, the farmers
mentioned that a paddy transplanter was so heavy that the user developed high
fatigue. In the case of failure of parts, the farmers could not repair or replace
them by spending affordable amount of money.

On the whole, while conducting the orientation phase, it was inferred

that the value of paddy transplanter was so low that it prevented its usage to a
good extent in practice. Since a team with farmers as members could not be
formed, a team consisting of nine members possessing proper expertise in fields
like industrial engineering, farm power machinery, food process engineering and
welding was formed. The constitution of this team is shown in Table 3.1.
The author of this thesis (who was also a team member) served as the team
leader. These team members reviewed the towards difficulties expressed by the
farmers while using the six row paddy planter in the field by application. At the
end of conducting this review, the team members suggested to increase the value
 22

of six row manually operated paddy transplanter by executing the remaining

phases by value engineering job plan.

Table 3.1 Value Engineering Team

Serial Name, Qualification Specialization Experience Other aspects

number and Designation held in Years
1 M. Mohan Mechanical 15 Life member
Senior Technical Engineering and in Indian
Officer, and Team Industrial Society of
Leader cum Engineering Agriculture
Coordinator, Engineering
and Associate
Central Institute of member in
Agricultural Institution of
Engineering, Regional Engineers
Centre, Coimbatore, (India).
India.
2 Dr. G. Sundararaj PhD Manufacturing, 33 Honorary
Associate Professor Instrumentation, Secretary of
Quality Institution of
Dept. of Mechanical Engineering, Engineers
Engg. Value (India)
PSG College of Engineering,
Technology, Safety
Coimbatore, India. Engineering
3 Dr. RavindraNaik Food 17 Life member
Senior Scientist Processing in Indian
Engineering Society of
Central Institute of Agriculture
Agricultural Engineering
Engineering, Regional and member
Centre, Coimbatore, in Institution
India. of Engineers
(India).
4 Sh. Veluchamy Production and 25 Member in
Managing Director Manufacturing Agricultural
Machinery
Magnificent Engineers Manufacturing
SIDCO Industrial Association
Estate
Coimbatore, India.
 23

Table 3.1 (Continued)

Serial Name, Qualification Specialization Experience Other aspects

number and Designation held in Years
6 Mr. G. Muruganandam Production 20 -
Technical Officer
Central Institute of
Agricultural
Engineering, Regional
Centre, Coimbatore,
India.
7 Mr. A.R. Jesuraj Fabrication 20 -
Sr. Technical Assistant
Central Institute of
Agricultural
Engineering, Regional
Centre, Coimbatore,
India.

8 Mr. S. Padmanaban Welding 20 -

Sr. Technical Assistant
Central Institute of
Agricultural
Engineering, Regional
Centre, Coimbatore,
India.
9 Mr. Balamurugan Manufacturing 15 -
Field Technician
Central Institute of
Agricultural
Engineering, Regional
Centre, Coimbatore,
India.

3.3 INFORMATION PHASE

After the team members suggested to improvise the six row manually
operated paddy transplanter, information phase was conducted. While conducting
the information phase, the constructed details of six row manually operated
 24

paddy transplanter were gathered. These constructional details are briefly

presented here. Six row manually operated paddy transplanter is a pull type
manually operated device. It is used to transplant mat type seedlings. The
photograph of mat type seedlings is shown in Figure 3.1. The schematic diagram
of six row manually operated paddy transplanter is shown in Figure 3.2.
As shown, the six row manually operated paddy transplanter consists of eleven
major assemblies namely main frame assembly, handle assembly, skid assembly,
offset link assembly, pivot arm assembly, feeder link assembly, picker assembly,
seedling feeder assembly, tray holder assembly, seedling tray assembly and tray
side support assembly. In total 60 components are assembled to produce these
11 major assemblies. As the title implies, the seedling tray of six row manually
operated paddy transplanter contains six rows for enabling the seedlings to get
transplanted. Photograph showing an operator operating the six row manually
operated paddy transplanter is presented in Figure 3.3. While operating the six
row manually operated paddy transplanter, seedlings are kept on the seedling
tray and the operator pushes the handle to enable picker to pick the pinch of
seedlings for planting in the puddle soil. As the handle is lifted back, the picker arm
is also taken back from the soil. These two steps form one stroke of operation.

Figure 3.1 Mat type paddy seedling

 25

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Figure 3.2 Six row manually operated paddy transplanter

Figure 3.3 Operation of six row manually operated paddy transplanter

3.4 FUNCTION PHASE

Function phase is the third phase of the value engineering job plan.
As the title implies, while carrying out this phase, the function of each
 26

component is required to be analyzed. After conducting this analysis, the

function of each component of the product under study is defined by pinpointing
its verb and noun. While pursuing the research being reported here, the function
of all the 60 components were defined. These components and their functions
thus defined are shown in Table 3.2. As shown, besides defining the function of
each component, its nature is classified either as basic or secondary. As these
titles imply, basic functions indicate that the component is to be used for carrying
out basic function of the product. Secondary function indicates that the
component is used to perform supporting functions of the product. These aspects
are delineated here by considering the component ‘skid mount’ as example.
As shown, ‘fix’ is the verb and ‘frame’ is the noun that would describe the
function of this component. The function of this component belongs to ‘basic’
type as its malfunctioning or failed functioning affects the performance or
stopping the operation of the six row paddy transplanter.

Table 3.2 Functions of the components of six row manually operated

paddy transplanter

Name of Name of the Number of Function Type

the sub- component components
assembly used Verb Noun B/S

Main Skid mount 4 Fix Frame B

frame
assembly Improve Fasten S
Middle Skid 2 Fix Frame B
mount
Improve fasten S
Connector 1 Joint Frame B
 27

Table 3.2 (Continued)

Name of Name of the Number of Function Type

the sub- component components
assembly used Verb Noun B/S

Pivot bracket 2 Joint Arm S

Base frame 2 Support Weight S
Joint Float S
Depth control 2 Stop movement S
bracket
Control Depth S
Feeding frame 2 Fix Tray holder B
clamp
Side frame 2 Support Tray holder S
Joint clamp S
Stopper 2 Stop Movement S
Rear frame 2 Support Weight B
Joint Base Frame S
Carry Carriage pipe S
Carriage pipe 1 Carry Seedling tray B
Facilitate Tray S
movement
Withstand Freewheel S
bracket
Carry Chain roller S
Free wheel 1 Hold Sprocket S
bracket
Facilitate Freewheel S
rotation
Chain roller 1 Guide Chain roller S
bracket
Facilitate Chain S
rotation
Brace 3 Arrest Bend S
Improve Rigidity S
 28

Table 3.2 (Continued)

Name of Name of the Number of Function Type

the sub- component components
assembly used Verb Noun B/S

Handle Handle grip 2 Facilitate Grip S

assembly
Handle 1 Lift Picker B
assembly
Receive Pull and S
Push load
Facilitate Movement S
Pin bracket 2 Hold Handle B
Locate Pin S
Facilitate Operating S
Handle pin 2 Arrest Handle B
Skid Skid guard 2 Facilitate Operating S
assembly
Avoid Struck S
Bottom skid 2 Support Weight B
Carry Assembly B
Comfort Float S
Facilitate Handling S
Top skid 2 Carry Assembly B
Support Weight B
Mount Frame B
Hold Connector B
Pivot Bracket 2 Joint Arm B
Offset Enable Actuate S
link
assembly Offset Link 1 Transfer Motion B
Joint Pivot Arm S
Adjustment 1 Enable Adjust B
Bracket
Joint Feeder link S
 29

Table 3.2 (Continued)

Name of Name of the Number of Function Type
the sub- component components Verb Noun B/S
assembly used
Pivot arm Pivot arm bush 2 Joint Offset link B
assembly
Facilitate rotation S
Hex Head bolt 2 Joint Offset link S
Transfer Motion S
Pivot arm 2 Carry Picker B
assembly
Suit Handle S
Joint bush S
Joint Clamp S
Stopper bar 2 Stop Movement B
Clamp 2 Joint Picker B
assembly
Facilitate Tilting S
Gusset 2 Avoid Bend S
Facilitate Strength S
Pivot Arm 1 Joint Pivot arm B
connector
Facilitate Connect S
Hinge 2 Facilitate Tilting B
Joint Clamp S
Feeder Pivot bush 2 Joint Pivot Arm B
link
assembly Facilitate Actuate S
facilitate Connector S
Feeder link 2 Connector Feeder B
bracket
Joint Pivot bush S
Joint Pivot bracket S
Transfer Movement B
Pivot bracket 2 Joint Feeder S
Facilitate Actuate S
 30

Table 3.2 (Continued)

Name of Name of the Number of Function Type
the sub- component components Verb Noun B/S
assembly used
Picker Picker handle 6 Joint Holder S
assembly
Increase length S
Transfer Seedling B
Receive Push load S
Receive Pull load S
Picker holder 6 Hold Square rod S
Adjust Length S
Fasten Picker rod S
Hold Nut S
Arrest Rotation
Picker square 6 Hold Picker B
rod
Adjust Length S
Press Seedling S
Picker 6 Pick Seedling B
Release Seedling root S
Bold 6 Fasten Square rod B
Comfort Adjust S
Capture Moving S
Nut 6 Fasten Bold S
Seedling Seedling 1 Push Seedling B
feeder feeder
assembly Facilitate Move S
seedling
Release Seedling root S
Actuate lever 1 Joint Feeder link B
bracket
Facilitate Actuating S
Receive Pull load S
Pivot bush 2 Joint Actuate lever B
Rotate Free wheel S
 31

Table 3.2 (Continued)

Name of Name of the Number of Function Type
the sub- component components Verb Noun B/S
assembly used
Tray Row guide 2 Facilitate Straight row S
holder I & II
assembly Easy Row S
identifying
Feeding frame 1 Hold Feeding frame S
holder
Increase Strength S
Hold Bolt S
Facilitate fix S
Feeding frame 1 Support Weight B
Facilitate Feed S
Carry Tray B
Allow Seedling S
Clamp 2 Fix Assembly S
Increase Strength S
Seedling Tray plate 1 Support Weight B
tray
assembly Feed Seedling B
Carry Seedling B
Slide Seedling B
Restrict Corrosion S
Divider plate 7 Make Rows B
Separate Seedling S
Guide Seedling S
Side stiffener 2 Improve Stiffness S
Restrict Seedling fall S
Tray guide 1 Guide Movement S
Front support 1 Support Seedling S
Avoid Falling S
Edge stiffener 1 Improve Stiffness S
Avoid Bend S
Centre 1 Improve Stiffness S
stiffener
Avoid Bend S
 32

Table 3.2 (Continued)

Name of Name of the Number of Function Type
the sub- component components Verb Noun B/S
assembly used
Tray side Tray support 2 Support Weight B
support
assembly Joint Tray S
Side carriage 2 Support Weight B
pipe
Locate Carriage pipe B
Facilitate Tray moving S
Free Bearing holder 1 Hold bearing B
wheel
assembly Arrest Bearing out S
Chain link 1 Rotate Sprocket B
Joint Sprocket S
Free wheel 1 Hold Free wheel B
holder
Fit Free wheel S
Facilitate Rotate S

B – Basic; S - Secondary

After identifying the functions, the team member examined the worth
of considering the assemblies for suggesting alternatives in the design and
improving their values. The team members realized that four assemblies namely
skid assembly, picker assembly, tray holder assembly and seedling tray assembly
had potential to improve their value by incorporating alternatives. Subsequently,
the team members determined the alternatives to improve the performance of
these four assemblies. Further, the team members identified the existing cost of
the assembly being used now and estimated the cost of assembly after
incorporating the alternatives. These information were used to carry out the
function cost worth analysis shown in Table 3.3. As shown, by considering the
function and cost, the value gap against each assembly was determined. Then the
potential for improving value was ranked by considering the value gap in
descending order. These ranks are indicated in the last column of Table 3.3.
 33

These ranks indicated the priority in choosing the assembly while conducting the
phases of value engineering job plan. As shown in Table 3.3, seedling tray
assembly was first ranked. This ranking indicated that seedling tray assembly
was required to be given highest priority while improving six row manually
operated paddy transplanter. On the other hand, tray holder assembly was to be
given least priority while improving the six row paddy transplanter as this
assembly was ranked fourth.

Table 3.3 Function cost worth analysis

Functions Existing Worth Value Rank

cost gap
Verb Noun (INR) Tentative Estimated
Alternate cost in (INR)
(INR)

Skid assembly

Arrest Handle 2000 May be made by 1500 500 II

plastic
Easy Movement

Avoid Struck

Support Weight

Carry Assembly

Comfort Float

Facilitate Handling

Carry Assembly

Support Weight

Mount Frame

Hold Connector
 34

Table 3.3 (Continued)

Functions Existing Worth Value Rank

cost gap
Verb Noun (INR) Tentative Estimated
Alternate cost in (INR)
(INR)

Picker assembly

Joint Holder 135 Design may be 67 68 III

simplified to
Increase length contain less
number of
Transfer Seedling
components.
Receive Push load

Receive Pull load

Hold Square rod

Adjust Length

Fasten Picker rod

Hold Nut

Arrest Rotation

Hold Picker

Adjust Length

Press Seedling

Pick Seedling

Release Seedling
root

Fasten Square rod

Comfort Adjust

Capture Moving

Fasten Bold
 35

Table 3.3 (Continued)

Functions Existing Worth Value Rank
Verb Noun cost Tentative Estimated gap
(INR) Alternate cost in (INR)
(INR)
Tray holder assembly 92 Sheet thickness 58.00 38.00 IV
Facilitate Straight may be reduced
row to 1.25
millimeters
Facilitate Straight
row
Hold Feeder
frame
Facilitate Feed
seedling
Fix Tray holder
Joint Side frame
Seedling tray assembly 1,194 Sheet thickness 469 725 I
Support Weight may be reduced
to 1.25
Feed Seedling millimeter and
Carry Seedling tray divider
Slide Seedling fixing process
may be carried
Restrict Corrosion out by
Make Rows employing spot
Separate Seedling welding
Guide Seedling
Improve Stiffness
Restrict Seedling
fall
Guide Movement
Support Seedling
Avoid Falling
Improve Stiffness
Avoid Bend
Improve Stiffness
Avoid Bend

In order to improve the picturaisation of the situations being studied,

Function Analysis System Techniques (FAST) diagrams were drawn against the
 36

four assemblies that were considered while conducting the investigation being
reported here. Each FAST diagram was drawn after developing function
spread sheet. These function spread sheets and FAST diagram are shown in
Tables 3.4-3.7 and Figures 3.4 – 3.7 respectively.

Table 3.4 Functions spread sheet of seedling tray assembly

Serial Functions Serial Functions

number number
Why How Why How
1 Support weight 10 Restrict falling
2 Feed seedlings 11 Guide movement
3 Carrying seedlings 12 Support seedling
4 Slide seedling 13 Avoid falling
5 Restrict corrosion 14 Improve stiffness
6 Make rows 15 Avoid bend
7 Separate seedling 16 Improve stiffness
8 Guide seedling 17 Avoid bend
9 Improve stiffness

Hold Restrict Restrict Improve

How Why
seedling corrosio falling stiffness

When
Avoid
bend

Carry Support Feed Slide Make

seedling weight seedling seedling rows

Guide Separate Guide

movement seedling seedling

Support Avoid
seedling falling

Scope of project

Figure 3.4 FAST diagram of seedling tray assembly

 37

Table 3.5 Functions spread sheet of skid float assembly

Serial Functions Serial Functions

number Why How number Why How
1 Easy Movement 6 Facilitate Handling
2 Avoid Striking 7 Carry Assembling
3 Support Weight 8 Support Weight
4 Carry Assembly 9 Mount Frame
5 Comfort Float 10 Hold Connector

How Why
Float Comfort Easy Avoid
equipment Float move Striking
When

Carry Support Mount Hold Facilitate

Assembly Weight Frame Connector Handling

Support Support
Weight Weight

Scope of project

Figure 3.5 FAST diagram of skid Assembly

 38

Table 3.6 Functions spread sheet of picker assembly

Serial Functions Serial Functions

number Why How number Why How
1 Joint Holder 11 Hold Picker
2 Increase Length 12 Adjust Length
3 Transfer Seedling 13 Press Seedling
4 Receive Push load 14 Pick Seedling
5 Receive Pull load 15 Release Seedling root
6 Hold Square rod 16 Tied Square rod
7 Adjust Length 17 Comfort Adjust
8 Tied Picker rod 18 Capture moving
9 Hold Nut 19 Tied Bold
10 Arrest Rotation

Transplant Joint
Release Comfort
Seedling holder
How seedling root adjustment Why

When
Receive Arrest
Hold
Push load movement
Square
rod

Hold nut

Transfer Pick Seedling Hold picker Tied square rod Increase

length
Seedling

Arrest
Fasten bolt rotation Adjust
length

Fasten bolt

Scope of project

Figure 3.6 FAST diagram of picker assembly

 39

Table 3.7 Functions spread sheet of tray holder assembly

Serial Functions Serial Functions

number Why How number Why How
1 Facilitate Straight row 7 Support Weight
2 Easy Row identifying 8 Facilitate Feed
3 Hold Feeding frame 9 Carry Tray
4 Increase Strength 10 Allow Seedling
5 Hold Bolt 11 Fix Assembly
6 Facilitate fix 12 Increase Strength

How Why

Hold Increase
Facilitate Make Row
Tray strength Straight row
When

Easy row
idea

Carry Tray Support Hold Fix Assembly Increase

weight Feeding rigidity
frame

Allow
seedling Hold bolt

Facilitate
feeding

Scope of project

Figure 3.7 FAST diagram of tray holder assembly

 40

3.5 CREATIVE PHASE

While executing the creative phase, the team members identify new
ideas and express suggestions which add value to the product that is under
consideration. In this regard, team members will consider the components based
on the rankings made in the function phase. In order to facilitate the team
members to express new ideas and suggestions, brainstorming technique is
frequently used during the conducting creative phase in value engineering
projects. While applying brainstorming technique, the team members meet in
one location and under the guidance of the team leader, express their ideas and
suggestions to add value in the product being under the consideration. This
meeting is regarded as brainstorming session. Depending upon the complexity
of the value addition to be considered in the product, one to several brainstorming
sessions are conducted in the creative phase of the value engineering programme.
While conducting the investigation being reported here, one brainstorming
session was conducted by involving all the team members. Before inviting the
team members to express their ideas and suggestions, the team leader described the
difficulties expressed by the farmers who are using the six row paddy transplanter.
These difficulties expressed by the farmers are enumerated in Table 3.8.

Table 3.8 Difficulties expressed by Farmers

Serial Difficulties expressed by the farmers

number
1 Difficult to pull the six row paddy transplanter in puddle soil.
2 Picker rod has to be replaced frequently as it gets damaged due to
collision with stones while operating six row paddy transplanter.
3 Picker rod required to be adjusted frequently with spanner.
4 Free-wheel mechanism enabling the tray movement gets struck due to
the mud getting on its slurry soil.
4 The float which is made of wood gets warpaged and damaged in the wet
soil due to change in climate.
5 The price of the six row paddy transplanter is high which prevents its
usage by the farmers who possess very little paying capacity.
 41

After studying, the team members focused their mind to express ideas
that would aid to overcome above difficulties. After that, the brainstorming
session was started and the new ideas expressed by the team members were
gathered. These new ideas are listed in Table 3.9.

Table 3.9 New ideas suggested by the team members

Idea Idea
Number
1 Seedling tray height can be reduced from 440 millimeters to 350
millimeters.
2 Seedling tray sheet thickness can be reduced from 2 millimeters to
1.25 millimeters.
3 Seedling tray divider may be made by employing spot welding
(currently it is riveted).
4 Tray support clamp may be manufactured by employing
aluminum die casting process.
5 Skid float may be made by plastics (now, it is made by wood).
6 Picker holder assembly may be simplified to reduce the parts.
7 Wing type bolt may be used for fixing picker rod.
8 Thickness of the frame of the seedling tray holder can be reduced
from 2 millimeters to 1.25 millimeters.
9 Gauge wheel arrangement may be made for easy pulling of the six
row paddy transplanter.
10 Index mechanism may be incorporated in the wheel to maintain
uniformity in the hill to hill distance of planting of seedlings.

Subsequent to the generation of new ideas, the team members were

invited to attend a meeting for developing the feasibility ranking matrix. This
feasibility ranking matrix developed by the team members is shown Table 3.10.
 42

As shown, five criteria namely ‘State of the art’, ‘Probability of implementation’,

‘Development cost, ‘Time to implement’ and Potential cost benefit’ were
considered. The feasibility of ideas against these criteria was indicated through
scores in a scale of range 1-10. Finally, the total score against each criterion was
calculated by summing the scores assigned by the team members against each
criterion. Then, the team members decided to consider the ideas whose total
score was 45 and above. As shown in Table 3.10, the total sore of ideas numbered
1, 2, 3, 5, 6 and 8 was 45 and above. Hence, those six ideas were considered in
the subsequent phases of applying vale engineering job plan. Those ideas are
listed in Table 3.11. According to those ideas, at the end of function phase, the
following five proposals were drawn.

Table 3.10 Feasibility Ranking Matrix

Idea Criteria Total

number State of art Probability of Cost to Time to Potential score
implementation develop implement cost benefit
(10: Off the (10: High (10: /RZ (10 : No time (10: High
shelf 1:New chance 1: No cost 1: +LJK 1: Maximum 1: Low)
technology) chance) cost) time)
1 10 10 8 10 10 48
2 10 10 7 10 10 47
3 8 9 10 9 10 46
4 7 7 8 7 8 37
5 8 8 10 10 9 45
6 8 10 10 9 9 46
7 8 9 8 9 9 43
8 10 9 9 9 8 45
9 5 6 8 8 4 31
10 7 8 7 6 4 34
 43

Table 3.11 Feasible ranked ideas

Idea Idea
Number
1 Seedling tray height can be reduced from 440 millimeters to 350
millimeters.
2 Seedling tray sheet thickness can be reduced from 2 millimeters to
1.25 millimeters.
3 Seedling tray divider may be made by employing spot welding
(currently it is riveted).
5 Skid float may be made by plastics (now, it is made by wood).
6 Picker holder assembly may be simplified to reduce the number of
parts.
8 Thickness of the frame of the seedling tray holder can be reduced
from 2 millimeters to 1.25 millimeters.

3.5.1 Reducing Height and Thickness of the Seedling Tray (Ideas 1

and 2)

The seedling tray was fabricated by galvanized iron sheet. Its height
was 440 millimeter. The thickness of the tray was 2 millimeters. The paddy
seedlings were kept on the seedling tray in six rows. Due to more height, more
seedlings were also kept on the tray with six rows. Hence, the user found it
difficult pull the six row manually operated paddy transplanter on wetland field.
Hence, it was suggested to reduce the height and thickness of the seedling tray
of the six row paddy transplanter.

3.5.2 Seedling Tray Divider may be made by Employing Spot

Welding (Currently it is Riveted) (Idea 3)

The seedling tray divider strips were fabricated with galvanized iron
sheet. This divider strip was fixed on the seedling tray by using riveted joints.
The divider was required to divide six rows in the seedling tray and also to
 44

improve the paddy mat seedling. The fixing of strip by riveted joints was
complicated and manufacturing time was also high. Hence, instead of riveting
the team members proposed to join the fixing divider strips by employ of spot
welding.

3.5.3 Skid Float may be made by Plastics (now, it is made by Wood)

(Idea number 5)

Float skid assembly of the six row manually operated paddy

transplanter consisted of three parts namely bottom skid, top skid and skid guard.
The main frame of the six row manually operated paddy transplanter fixed on
the top skid and the total top skid was fixed on bottom skid. The skid guard was
fitted in the front side float and it aided to move easily on wetland. These were
made by Sal wood. The cost of fabricating wooden skid float was higher and the
labour cost involved was also more. It was found that the plastic molded bottom
skid float assembly is used in power operated paddy transplanter which is readily
available in the market. It was proposed to adopt this plastic molded skid float
which is cheaper and compact compared to the wooden skid float.

3.5.4 Picker Holder Assembly may be Simplified to Reduce the

Number of Parts (Idea number 6)

Picker holder assembly of six row manually operated paddy

transplanter consisted of three parts namely picker rod, square rod and square
tube for holding the square rod. Spring material of the picker rod was welded
with square rod and the square rod along with picker rod was inserted in the
square tube and was tightened with bolt. The entire picker holder assembly was
fixed with finger tube end. The square rod along with picker could adjust picking
length by adjusting the bolt. According to the alternative proposed by team
members, instead of fabricating three parts of picker holder assembly, the picker
rod length could be increased. According to this proposal, the picker would be
 45

inserted in the picker handle only if the picker handle end formed was wedge
shaped.

3.5.5 Thickness of the Frame of the Seedling Tray Holder can be

Reduced (Idea number 8)

The seedling tray holder was rest on the transplanter main frame and
held the seedling tray. The thickness of the sheet is was high. Hence, it was
proposed to reduce the thickness of sheet is seedling tray holder. The reduction
of the sheet thickness of seedling tray was not found to affect the holding of the
seedlings.

3.6 EVALUATION PHASE

In order to evaluate the new ideas with the existing practices, pair-
wise comparison matrix needs to be developed. While carrying out the
investigation being reported here, in order to develop this matrix, it was required
to interview the farmers for gathering their preferences over the parameters to be
considered for improvising the working of six row manually operated paddy
transplanter. For example, a farmer had to be enquired whether he or she would
prefer the parameter ‘reducing weights or reducing cost’ and to which extent this
preference would be made. As the farmers are illiterate, this exercise could not
be carried out. In this background, the team leader developed the parameters and
their codes. Those parameters and codes are shown in Table 3.12.

Subsequently, the team leader developed points by comparing the

parameters. The scale used to develop these points is shown in Table 3.13.
By using the scale, the comparative points were developed. These comparative
points are presented in Table 3.14. As shown, the comparative points are shown
as suffices of the codes by the parameters. For example, in the first row of this
matrix, ‘A3’ is indicated in the cell intersecting the cells with the codes of
parameters namely A and B. Here A3 indicates that the parameter ‘reducing
 46

weight’ which is coded as A is major difference in comparison to the parameter

‘reducing cost’ which is coded as B. Finally, in the list column of this
comparative matrix, the total score against each parameter is indicated. These
total scores were determined by adding the points of the parameters. For
example, in the first row, the points A3 and A2are presented. Here, the total score
of parameter is, 3+2 = 5. These total scores were used to rank the preferences of
each parameter over other parameters.

Table 3.12 Parameters and Codes

Code Parameters
A Reducing weight
B Reducing cost
C Reducing the number of parts
D Easy to operate
E Farmer satisfaction
F Improve life
G Easy to maintain
H Farmer accessibility

Table 3.13 Scale for identifying the comparative difference

Scale Points
Major difference 3
Medium difference 2
Minor difference 1
No difference 0
 47

Table 3.14 Comparative points and total score of parameters

A B C D E F G H Total
score
A A3 C2 D2 E3 F3 A2 H3 5
B B3 B3 E2 B2 B3 H2 11
C C3 E1 F2 C3 C2 10
D D2 D3 F2 D1 8
E F2 E3 E2 11
F F2 H3 11
G G3 3
H 10

3.6.1 Evaluation Matrix

In order to rank the ideas, the weights of the same have to be estimated
and subsequently the weighted sums have to be calculated. While executing the
investigation being reported here, the scale that was used to indicate the weight
of the ideas is shown in Table 3.15. After estimating the weight of each idea, the
sum of the product of the weight and total score of the parameters were
determined. This calculation is shown in Table 3.16. As example, the calculation
of the weighted score against the idea numbers 1 and 2 shown in this table is
illustrated here. As shown in this table, the weight of these ideas are indicated as
3,4,2,4,3,2,2 and 4. Those values are indicated in the top left corner of each cell.
The corresponding total score (which is drawn from Table 3.14) is indicated in
brackets. The calculation of weighted same against this criterion is shown below.

Weighted sum of idea numbers 1and 2 = 3×5 = 15 against the

parameter, reduced weight.

Sums of weighted score of idea numbers 1 and 2 =

15+44+20+32+33+22+6+40 = 212
 48

The sums of the weighted score were used to decide the ideas which
were to be suggested for implementation.

Table 3.15 Scale for identifying weight of the parameters

Scale Weight of the parameters

Excellent 4
Very Good 3
Good 2
Fair 1

Table 3.16 Determination of the weighted score of ideas

Idea Idea Parameters and total scores (in brackets) Sum of

number Reduced Reduced Reduced Easy to Farmer Improve Easy Farmer weighted
weight cost (11) part (10) operate satisfaction life of maintenance accessibility score
(5) (8) (11) machine (3) (10)
(11)
1 Seedling tray 3 4 2 4 3 2 2 4
and 2 height and 212
thickness can be
reduced. 15 44 20 32 33 22 6 40
3 Seedling tray 2 5 4 3 3 3 2 3
divider may be 231
made by
employing spot
welding
(currently it is
riveted). 10 55 40 24 33 33 6 30
5 Skid float may be 3 4 3 4 3 4 4 4 250
made by plastics
(now, it is made
by wood). 15 44 30 32 33 44 12 40
6 Picker holder 3 4 4 3 3 3 3 3 228
assembly may be
simplified to
reduce the parts
15 44 40 24 33 33 9 30
8 Thickness of the 2 3 1 2 2 2 2 2 139
frame of the
seedling tray
holder can be
reduced. 10 33 10 16 22 22 6 20

3.7 RECOMMENDATION PHASE

While executing this phase, it was decided to recommend the

implementation of ideas whose sums of weighted score exceeded the value 100.
Since as shown in Table 3.16, all the sum of weighted score of ideas exceeded
the value 100. It was decided to implement all the ideas in the implementation
phase.
 49

3.8 IMPLEMENTATION PHASE

While executing this phase, the chosen ideas were subjected

implementation. On implementing ideas 1, 2, 3, 5, 6 and 8 the cost as well as
weight of the assembles and parts could be reduced. These details are presented
in the following subsections.

3.8.1 Reducing Height and Thickness of the Seedling Tray (Ideas 1

and 2)

The height and thickness of seedling tray were reduced from 440
millimeter to 350 millimeter and 2 millimeter to 1.2 millimeter respectively.
These details are shown in Figure 3.8. The specifications of p and modified
seedling tray cost reduction achieved are shown in Table 3.17. As shown, the
weight and cost reduction achieved by applying the value engineering job plan
were 4.49 kilogram and INR 359 respectively. The percentage weight reduction
and cost reduction were 52.69 and 52.71 respectively.

Figure 3.8 Seedling tray height and thickness reduced

 50

Table 3.17 Specifications and cost reduction

Serial Seedling tray which was Modified seedling tray

Number previously used
1 Size 1240 × 440 1240 × 350 millimeters
millimeters
2 Material Galvanized iron Sheet thickness reduced to
Sheet, 2 1.25 millimeters
millimeters
thickness
3 Number of rows 6 6
4 Weight 8.52 4.03
(kilogram.)
5 Material cost per INR 80 INR 80
kilogram
6 Material cost INR 681 INR 322
(weight ×
material cost per
kilogram)
7 Weight reduction 8.52– 4.03 = 4.49 kilograms
(kilogram)
8 Cost reduction 681 – 322 = 359
INR)
9 Percentage of (4.49 ÷ 8.52) × 100 = 52.69 percentage
weight reduction
10 Percentage of (359 ÷ 681) × 100 = 52.71 percentage
cost reduction

Calculation:

Length of the tray = 1240 millimeter = 124 centimeters

Height of the tray = 350 millimeter = 35 centimeters

Thickness of the tray = 1.25millimeter = 0.125 centimeters

Weight = volume × density

Volume = Length × Height × Thickness

= 124 × 35 × 0.125 centimeters

= 542.5 centimeter3

Weight = 542.5 × 7.424 = 4027.52 gram = 4.03 kilograms

 51

3.8.2 Seedling Tray Divider may be made by Employing Spot

Welding (Currently it is Riveted) (Idea 3)

As the result of evolving idea 3.18, the riveting process was replaced
by spot welding to join the tray divider. The seedling tray after employing spot
welding process is shown in Figure 3.9. By using spot welding process, the
production rate is increased and cost of labour is reduced. The cost and weight
reduction achieved by implementing this idea is presented in Table 3.18.
As shown, as the result of implementing idea 3, the weight and cost reduced in
the six row manually operated paddy transplanter were 1.26 kilogram and INR 366.
The percentage weight and cost reduction were respectively 52.5 and 71.34.

7UD\GLYLGHUMRLQHGE\UHYHUWLQJ

7UD\GLYLGHUMRLQHGE\VSRWZHOGLQJ

Figure 3.9 Seedling tray divider joined by reverting and

spot welding process
 52

Table 3.18 Comparison between rivet and spot welding of

seedling tray divider

Serial Seedling tray divider which was earlier Seedling tray divider
Number riveted being spot welded
1. Size 440 millimeters × 50 Tray divider length
millimeters – 7 reduced to 350
dividers millimeters
2. Thickness of the 2 millimeters 1.25 millimeters
galvanized iron
sheet
3. Number of dividers 7 7
4. Weight 2.4 kilograms 1.14 kilograms
5. Material Cost (INR) 192 91
6. Number of rivets 6 per divider; Number of spotted welds
6 × 7 = 42 rivets –4
4 × 7 = 28
7. Cost for rivets and INR 21 + INR 300 Spotted welding cost INR
labour for fixing the = INR 321 2 per spot weld;
divider Cost = INR 2 x 28 = INR
56
8. Weight reduction 2.4 – 1.17 = 1.26
(kilogram)
9. Cost reduction 513 – 147 = 366
(INR)
10. Percentage of (1.26÷2.4) × 100 = 52.5
weight reduction
11. Percentage of cost (366 ÷ 513) × 100 = 71.34
reduction

3.8.3 Skid Float may be made by Plastics (now, it is made by wood)

(Idea number 5)

As mentioned earlier, before applying of value engineering job plan

the skid float assembly was fabricated by using Sal wood. Usage of skid float
made of Sal wood increased the weight of six row manually operated paddy
transplanter. According to idea 5, in order to overcome this problem, skid float
made of plastic had to be used. A search indicated that skid float made of plastic
 53

is being used in power drivers paddy transplanter. Hence, this readily available
plastic skid float was purchased from market and fitted in the newly developed
six row manually operated paddy transplanter. The skid float made of Sal wood
and the plastic skid float procured from the market are shown in Figure 3.10
and 3.11 respectively. The cost and weight reduction achieved due to the
purchase of readily available plastic skid float is shown in Table 3.19. As shown,
the cost and weight reduction achieved was INR 500 and 0.5 kilograms
respectively. The percentages of cost and weight reduction achieved due to the
implementation of this idea were 25 and 11.1 respectively.

7RSVNLG
%RWWRPVNLG
RWWRP VNLG
G
3ODVWLF
PROGHG
6LGHJXDUG
VNLG

Figure 3.10 Sal wood skid float Figure 3.11 Plastic skid float purchased
from the market
Table 3.19 Cost and weight reduction due to the adoption of
plastic skid float

Serial Wooden skid float Plastic skid float

number
1 Material used Sal Wood Plastic molded
2 Weight 4.5 kilogram 4 kilogram (left and
(left and right) right)
3. Cost (including material INR 2,000.00 INR1500.00
labour)
4. Weight reduction 4.5 – 4 = 0.5
(kilograms)
5. Cost reduction (INR) 2000 – 1500 = 500
6. Percentage of weight (0.5÷4.5) × 100 = 11.1
reduction
7. Percentage of cost (500 ÷ 2000) × 100 = 25
reduction
 54

3.8.4 Picker Holder Assembly may be Simplified to Reduce the

Number of Parts (Idea number 6)

Previously the picker holder assembly of six row paddy transplanter

was made of three parts. On implementing idea number 6, the number of parts
was reduced to two. The previously used and modified picker holder assembly
are shown in Figures 3.12 and 3.13 respectively. On implementing two ideas, the
labour cost was reduced from that is incurred now. The cost and weight achieved
is shown in Table 3.20. As shown, the cost and weight reduction achieved on
adopting the modified picker holder assembly were INR 68 and 0.22 kilograms
respectively. The percentages of cost and weight reduction achieved by
implementating idea number 6 were 50.37 and 33.42 respectively.

0RGLILHGSLFNHU
3LFNHUKROGHU
KROGHU
DVVHPEO\

Figure 3.12 Previously picker Figure 3.13 Modified picker

holder assembly holder assembly
 55

Table 3.20 Specifications and achievement of weight and cost reduction in

the picker holder assembly

Serial Picker rod assembly previously used Modified picker rod assembly
number
Particulars Cost in Particulars Cost in
INR INR
1. Number of picker handles – 6 16 Number of picker handles – 6 25
(Weight = 0.217 kilogram) (Weight = 0.342 kilogram)
2. Number of picker holders – 6 21 - 0
(Weight = 0.2699 kilogram)
3. Number of picker slid square 10 - 0
rods – 6
(Weight = 0.15 kilogram)
4. Number of picker rods – 6 1 Number of picker rods – 6 5
(Weight = 0.0213 kilogram) (Weight– 0.0973 kilogram)
5. Number of bolts and nuts – 06 12 Number of wing nuts - 6 12
6. Labour cost for fabrication 06 75 Labour cost – 1 hour 25
numbers – 3hours (INR 200 per 8 hours)
(INR 200 per day) – 8 hours
per day
7. Weight reduction (kilograms) 0.6582 – 0.4393 = 0.22
8. Cost reduction (INR) 135 – 67 = 68
9. Percentage of weight reduction (0.22 ÷ 0.6582) × 100 = 33.42
10. Percentage of cost reduction (68 ÷ 135) × 100 = 50.37

3.8.5 Thickness of the Frame of the Seedling Tray Holder can be

Reduced (Idea number 8)

In order to implement idea number 8, the thickness of the seedling

tray holder frame which was reduced from 2 millimeters to 1.25 millimeters.
This implementation is indicated Figure 3.14. The specifications and reduction
of cost and weight due to the implementation of this idea in the seedling tray
holder frame are presented in Table 3.21. As shown, due to implementation of
idea number 8, the reduction of cost and weight achieved were INR 34 and 0.431
kilogram respectively. The percentages of reduction in cost and weight achieved
due to the implementation of this idea are 36.95 INR and 37.48 kilograms
respectively.
 56

6KHHWWKLFNQHVVUHGXFHG
IURPPLOOLPHWHUVWR
PLOOLPHWHUV

Figure 3.14 Seedling tray holder frame

Table 3.21 Comparison between previously used and modified of

seedling tray holder frame

Serial Seedling tray holder frame which was Modified seedling

number previously used tray holder frame
1. Thickness of 2 millimeter 1.25 millimeters
the Galvanized Size – 1240 × 59 × 2
iron sheet millimeters
material
2. Weight 1.15 kilograms 0.719 kilogram
3. Cost 92.00 (INR 80 per kilogram) INR 58
4. Weight 1.15 – 0.719 = 0.431
reduction
(kilograms)
5. Cost reduction 92 – 58 = 34
(INR)
6. Percentage of (0.431 ÷ 1.15) × 100 = 37.48
weight
reduction
7. Percentage of (34 ÷ 92) × 100 = 36.95
cost reduction
 57

3.9 AUDIT PHASE

The cost reduction achieved through the incorporation of the chosen

ideas in the six row manually operated paddy transplanter is summarized in the
Table 3.22. As shown, the total cost reduction on implementing the ideas was
found to be INR 1327. This cost reduction was required to be audited by the team
members jointly with the financial accountants of the company. Since not many
units of six paddy transplanter incorporated with the new ideas have so far been
produced, this auditing exercise could not carried till the time of writing this thesis.
Yet, the corrosion test on picker rod was conducted. The report on this test as shown
in this thesis. As shown the corrosion is not high on the picker rod.

Table 3.22 Cost reduction achieved in the six row manually operated
paddy transplanter through the implementation of the chosen ideas

Idea Idea Cost reduction

number achieved in
(INR)
1 and 2 Seedling tray height and thickness are reduced 359
3 Seedling tray divider may be made by 366
employing spot welding.
5 Skid float may be made by plastics (now, it is 500
made by wood)
6 Picker holder assembly may be simplified to 68
reduce the parts
8 Seedling tray holder frame sheet thickness can 34
be reduced.
Total cost reduction 1327

3.10 CONCLUSION

Time and again, researchers have reported the incorporation of

automation in the paddy transplanter machine (Bakker et al. 2010). Some of these
machines are commercially available in developed countries like the USA and
England. Although these automated machines significantly increase the speed of
 58

paddy transplantation, the high capital cost as well as running cost have been
preventing their widespread usage in the world. Particularly in the countries like
in India, farmers with very little cultivation land are unable to financially afford
for employing automated paddy transplanting machine. Hence, farmers in
countries like India need to be provided with either manually or semi-automated
paddy transplanter. However, in order to ensure its widespread usage, such
paddy transplanter should be made available for lesser price and made easier for
handling. In the context of in this derivation, the investigation reported in this
chapter was carried out on six row manual operated paddy transplanter. In order
to improve the value of this transplanter, value engineering job plan applied.
Through this approach, appropriate information were gathered and the same
were analyzed using appropriate techniques.

The outcome of this analysis indicated the need to modify the design
of five parts of this paddy transplanter namely seedling tray, skid float, picker
holder assembly, seedling tray holder frame and seedling tray divider fixing so
as to reduce the cost, weight and number of components. Subsequently ten ideas
were evolved. Out of them, six were chosen for implementation. The implementation
of these six ideas marked the application of value engineering job plan on the six
row manually operated paddy transplanter. In total, through the application of
value engineering approach, 31.12% of cost reduction in manufacturing of the
six row manually operated paddy transplanter could be achieved. Further, the
weight of this transplanter was reduced by 33.23%. Besides the eight components
used in the six row manually operated paddy transplanter could be avoided in the
newly manufactured six row manually operated paddy transplanter. These outcomes
would not only make the manually operated six row paddy transplanter affordable to
the farmers but would also make it easier to operate and maintain. It is due to the
reason that suppliers play crucial role in ensuring the successful development
and commercialization of newly designed products (Dobrzykowski et al. 2011).