session 4 reverse engineering and redesign
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8/13/2019 Session 4 Reverse Engineering and Redesign
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Session 4
Reverse Engineering and Redesign
Dr. Ing. Sheila Lascano Farak
Engineering Design Methodology:
A Global Perspective
8/13/2019 Session 4 Reverse Engineering and Redesign
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Outline
General Reverse Engineering and RedesignMethodology
Types of Redesign
Reverse Engineering & Product Dissection Dissection Process
Dissection Steps
Dissection Reporting Disassembly Plan
Bill of Materials
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Reverse Engineering:
• Reverse engineering starts with a current product andis the process of understanding the components,
functions, mechanisms, and systems used by theproduct.
• Reverse Engineering gives an overall picture of howother designers have combine parts to satisfy thecustomer needs.
Redesign Process:
• It is a process that follows reverse engineering, wherethe product is evolved to its next offering in the market.
Definitions
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Fixes
• A fix is a design modification that is required due to less than
acceptable performance once the product has been introducedinto the marketplace.
• Example: redesign of refrigeration systems (use of fluorinatedhydrocarbon refrigerants because of the “ozone-hole problem”)
Updates
• Updates are usually planned as part of the product’s life cyclebefore the product is introduced to the market.
• An update may add capacity and improve performance to theproduct or improve its appearance to keep it competitive.
Definitions
Redesign: There are two categories of redesigns:
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General Reverse Engineering and Redesign
Methodology
Reverseengineering
Modelingandanalysis
Redesign
Reverse engineering and redesign methodology has three distinct phases:
This approach allows us to understand the product.
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Investigation,
Prediction &
Hypothesis
Concrete experience:
Function & form
Design models
Design analysis
Parametric
Redesign
Adaptive
Redesign
Original
Redesign
ReverseEngineering
Modeling &
Analysis
Redesign
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Types of Redesign
Adaptive Redesign
(synthesis)
Involves adapting a known system to a
changed task or evolving a significant sub-
system of a current product.
Parametric Redesign
(modification)
Involves varying the parameters (size,
geometry, materials, etc..) of certain aspects
of a product to develop a new and more
Robust design.
Original RedesignImplies that a product already exists that isperceived to fall short in some criteria and a
new solution is needed.
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Reverse Engineering & Product
Dissection
Discover the operationalrequirements of the
product
How does the product operate?What conditions are necessary for proper function of the
product?
Examine how the product
performs its functions
What mechanical, electrical, control system or other devices are
used in the product to generate the desired functions?
What are the power and force flow through the product?
What are the spatial constraints for subassemblies andcomponents?
Is clearance required for proper functioning? If a clearance is
present, why is it present?
Determine the
relationships between
component parts of the
product.
What is the product’s architecture ?
What are the major sub-assemblies?
What are the key component interfaces?
Determine the
manufacturing and
assembly processes used
to produce the product.
Of what material and by what process is each component
made?
What are the joining methods used on the key components?
What links and fasteners are used and where are they located?
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The most important aspect of a product dissection is to make clear
why we are doing it.
What are the objectives of this activity?
What are the purposes of the new, evolved product?
What is expected to be uncovered through the dissection?
It is always fun to tear apart mechanical devices; however,
nothing will be accomplished if data are not collected on
important factors
Dissection Process
???
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STEP 1: List the Design Issues If it is a new product, the design issues may be unknown
Investigate: Customer market, competitors, features of competitors
products
If the project entails a redesign, an investigation can ask of theprevious team:
What was difficult for them?
What design problem did they solve that they are proud of?
What related technologies were they interested in?
Last set of design issues that needs recording is basic
information on the components in the assembly
Quantity of parts, dimensions, weight, material, color/finish,
manufacturing process, geometric tolerances, primary function, etc.
Dissection Steps
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STEP 2: Prepare for Product Dissection
Identify:
All sensors and test equipment required for measurement process
Camera
Videotape (of product operating)
Multimeter
Hardness tester
Optical sensor
Flow meter
Dynamometer
Calipers
Strobe
Etc.
Dissection Steps
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STEP 3: Examine the Distribution and Installation
Examine means used to:
Acquire parts
Contain parts
Ship, distribute, and market the product
Examine also:
the distribution packaging of the product
Consumer installation instructions and procedures (for cost,effectiveness and liability)
Dissection Steps
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STEP 4: Disassemble, Measure, and Analyze Data byAssemblies
First take pictures and measurements on the whole assembly
before disassembly
Then
Take apart the assembly
Take pictures in a exploded view
Take measurements on the parts and assemblies to complete thedata sheet
In this step is important to avoid destructive testing during the
first iteration.
Dissection Steps
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STEP 5: Form Bill a Materials (BOM)
During disassembly, the team should complete a written form
that details the product.
Add a sequence of assembly photos.
The data collected in each column of the BOM area that required
for subsequent analyses, including cost and performance.
Dissection Steps
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Disassembly PlanProduct Disassembly
Project name
Engineer(s)
Date:
Known Desired Information
Disassembly Plan:
Step Task Needed Tools
Measurements
Comparison with Predictions
*Could be components, features, physics, functions
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Bill of Material (BOM)
Bill of Materials
ProjectName
Engineer(s):
Date
Part # Name Qty
Functional Analysis DFM Cost Analysis
Function Flows-In Flows-Out Manuf. Process Dimensions Mass Material FinishOther
variable
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References
Otto , K . and K . Wood , Product Design:Techniques in Reverse Engineering and New
Product Development , Prentice Hall, Upper
Saddle River, NJ , 2001.
Dieter, G and Schmidth L. Engineering Design,,
Fourth Edition, Mc Graw Hill, New York, NY,
2009.
8/13/2019 Session 4 Reverse Engineering and Redesign
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Resources
https://sites.google.com/a/umn.edu/me2011/resources/product-dissection
http://www.mne.psu.edu/lamancusa/html/ProdDi
ss.htm
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