**3.2.5 Measure and test (information on the components)**

At this phase, we identified the applicability of DFMA during the components analysis, observing:


The operation of the locks used in the company was observed on their own ovens. The German lock was observed as how it works, once it could be assembled on its original oven. As for the Italian lock, it was possible to observe only through a simple manual fitting.

The DFMA applicability analysis were carried out and, once the company doesn´t produce the lock components, it has been asked the expert professionals´ help in manufacturing processes of this kind of component, once they work at two machining companies in the region.

#### **3.2.6 Specify and document**

The proposal of a new lock has been modeled through a parametric design software and taking into consideration the information from the previous phases, it has been defined the new product. Each of the new components has been designed, registered and documented accordingly.

#### **3.2.7 Prototyping**

All the lock components were prototyped at Federal University of Itajubá (UNIFEI), at the Dimension SST 768 machine, by the Fused Deposition Modeling (FDM), as Figure 6 shows.

#### **3.2.8 Review results**

As described in literature, the project went through all the previous phases and, upon completion of these phases, the prototype could be shown to the research team. Having identified new needs, it was necessary to return to some of the previous phases for reassessment and redesign. After repeating this cycle many times, the final design concept was realized, as shown in Figure 7.

200 Reverse Engineering – Recent Advances and Applications

**BEFORE AFTER** 

Table 3. Comparison between the current system and the proposed one for the oven lock.

At this phase, we identified the applicability of DFMA during the components analysis,

The operation of the locks used in the company was observed on their own ovens. The German lock was observed as how it works, once it could be assembled on its original oven. As for the Italian lock, it was possible to observe only through a simple manual fitting.

The DFMA applicability analysis were carried out and, once the company doesn´t produce the lock components, it has been asked the expert professionals´ help in manufacturing processes

The proposal of a new lock has been modeled through a parametric design software and taking into consideration the information from the previous phases, it has been defined the new product. Each of the new components has been designed, registered and documented

All the lock components were prototyped at Federal University of Itajubá (UNIFEI), at the Dimension SST 768 machine, by the Fused Deposition Modeling (FDM), as Figure 6 shows.

As described in literature, the project went through all the previous phases and, upon completion of these phases, the prototype could be shown to the research team. Having identified new needs, it was necessary to return to some of the previous phases for reassessment and redesign. After repeating this cycle many times, the final design concept

of this kind of component, once they work at two machining companies in the region.

Name: Spring Material: Spring steel Proposed manufacture: Spring adjustment

Function/feature: housed in the base and triggered by the rotating component, it makes there is a fast return to the initial position after its drive.

Name: Spring Material: Spring steel Manufacture: Spring

adjustment

the holes.

observing:

premature wear;

alternative materials;

layout of the factory floor.

**3.2.6 Specify and document** 

accordingly.

**3.2.7 Prototyping** 

**3.2.8 Review results** 

was realized, as shown in Figure 7.

components number reducing;

Function/feature: to press the housed spheres in the rotating component, so both stages may happens through

**3.2.5 Measure and test (information on the components)** 

equipment needed for manufacturing, quality and handling;

Fig. 6. Prototyped components of the proposed lock system

Fig. 7. Exploded view of the proposed design concept for a locking system

Integrating Reverse Engineering and Design for Manufacturing

Adaptor set

Main support and coil support

Support plate glass and display

> Mug (external wrapping)

Table 4. Diagnosis of the parts considered in the redesign

and Assembly in Products Redesigns: Results of Two Action Research Studies in Brazil 203

Manual welding of wires on the adaptor (component injected in ABS). During welding, it could happen the melting of the component in ABS because of being close to the welding equipment, causing non-compliance of

the component.

ABS injection.

The sets were assembled through welding, which if underdone could cause noncompliance on some components produced by

For being welded linked, when a non-compliance occurs on some components, the disassembling may cause loss of one or two of the sets.

The assemble of steel plate, display and glass is very difficult, once the clean glass can be touched by the assembling employees, being

disassemble for new cleaning. The display is made on aluminum (more expensive than steel, for example) and its manufacturing process needs stamping and a complete silk-screen process for recording of traces of marking time and engraving for the black and white

A different model of mug for any of the three models of hour meters, available for trade (one with lighting with rubber cushioning, another without lighting and another with a smaller size for a

stained, forcing its

painting.

specific client).

**Set/Component Illustration Difficulties** 
