**3.3.3 Team building**

Table 5 shows a group of research formed for the development of work at the company B.


Table 5. Research Team at Company B

## **3.3.4 Disassemble (information about the product)**

The studied hour meter has 11 systems and 87 components as a whole. For the redesign of this product, through reverse engineering, the reference product was totally disassembled, so the research group could analyze its constructive aspects, materials, (probable) assembling process, number of components etc.

The reference product analysis revealed several technical information that could be useful in the comparison of the components similar to the studied hour meter. Table 6 shows a comparison between some of these components.

#### **3.3.5 Measure and test (information on the components)**

After being disassembled the product, adopted as a reference, has been reassembled and taken to the lab of the company for testing the burn-in, among others. Some tractor model panels have been bought for testing the installation of the redesigned hour meter.

After this analysis, several meetings among the components of the research group were carried out in order to try to incorporate solutions to the current product, based on the reference product analysis and on the DFMA principles, to improve its assembling process and its cost-goal.

#### **3.3.6 Specify and document**

The studied company produced three hour meters models, one of them being to serve a client with a smaller mug (the mug is the wrapping that protects all the other components and helps in the fixation of the hour meter on the tractor panel), one with lighting and a damping rubber and another without lighting (for these two, the mugs are different to hold, or not, on their base a socket set for the bulb).

204 Reverse Engineering – Recent Advances and Applications

Table 5 shows a group of research formed for the development of work at the company B.

engineering

engineering

Graduate student in mechanical engineering

Sales manager Business management More than five years at the

Quality manager Technician More than 20 years on the

The studied hour meter has 11 systems and 87 components as a whole. For the redesign of this product, through reverse engineering, the reference product was totally disassembled, so the research group could analyze its constructive aspects, materials, (probable)

The reference product analysis revealed several technical information that could be useful in the comparison of the components similar to the studied hour meter. Table 6 shows a

After being disassembled the product, adopted as a reference, has been reassembled and taken to the lab of the company for testing the burn-in, among others. Some tractor model

After this analysis, several meetings among the components of the research group were carried out in order to try to incorporate solutions to the current product, based on the reference product analysis and on the DFMA principles, to improve its assembling process

The studied company produced three hour meters models, one of them being to serve a client with a smaller mug (the mug is the wrapping that protects all the other components and helps in the fixation of the hour meter on the tractor panel), one with lighting and a damping rubber and another without lighting (for these two, the mugs are different to hold,

panels have been bought for testing the installation of the redesigned hour meter.

**Member Formation Experience** 

He works on product developing processes for more than 4 years.

Mechanical projects expert.

Mechanical projects designs.

trade of the hour meter.

quality control.

hour meter production and

**3.3.3 Team building** 

Scientific initiation scholarship (two)

and its cost-goal.

**3.3.6 Specify and document** 

or not, on their base a socket set for the bulb).

Research coordinator Doctor in industrial

Researcher Doctor in industrial

**3.3.4 Disassemble (information about the product)** 

assembling process, number of components etc.

comparison between some of these components.

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

Table 5. Research Team at Company B


Table 6. Comparison of components between the studied hourmeter and the reference one

One of the group suggestions was to propose as well a single mug for the hour meter, to be projected. Other similar analyses were carried out for another sets and components. All the suggestions offered by the research group were documented and the changes on the components or sets were specified. Table 7 shows some of the proposed solutions for the company as a result of the product redesign.

Integrating Reverse Engineering and Design for Manufacturing

similar do the original product (union by welding).

**3.3.8 Review results** 

learned lessons.

**4. Discussion** 

**4.1 Company A** 

in the core of the interventions.

on the components number.

resulting in a total time of 220 minutes.

of 68%) for the system assembling.

and Assembly in Products Redesigns: Results of Two Action Research Studies in Brazil 207

The tests have provided opportunities for improvement on the redesigned components. For example, the vibration test showed that the sets together by snaps showed a performance

This assured the company owners that the alteration proposals could be taken forward, minimizing the risks of failure. This information was registered on the company database as

According to Coughlan and Coughlan (2002) the data critical analysis aspect in the actionresearch is that it is cooperative, and the researcher and the members of the client system

Such cooperating approach is based on the supposition that cooperators know much better their company, they know what is going to work and, mainly, they will be the ones to implement and follows the actions to be implemented. So, their involvement is crucial.

In this way, the criteria and tools for analysis were discussed between the researcher and his team of cooperators in the companies, so to be directly linked to the purpose of the research

Twelve aspects were identified for comparison of the final results between the current lock

The current lock has 13 components, as it is necessary two spheres and two springs. This is not necessary on the new lock, which has 11 components, representing about 15% reduction

As for the current lock they use five manufacturing processes: laser cutting, bending, machining, welding and spring arrangement. As for the new lock, there are only four: plastic injection, machining, spring arrangement and casting, a 20% reduction on the process number. The current lock manufacturing time was informed by the supplier, which makes the product, involving the laser cutting, machining, welding, spring arrangement and finish,

Beyond the manufacturing, the set assemble is also made by this supplier and the lock needs

Making contact with suppliers, discussing methods and making estimates for the new lock, one can estimate costs in around \$ 45.00 (a 64% cost reduction) involving all the necessary components and the time for manufacturing all the components and the necessary time for manufacturing them in around 20 minutes (a 91% reduction on the manufacturing time). Through the machined assembled prototype, one can estimate a 150 seconds time (reduction

around 480 seconds to be ready for order. This service whole cost is of \$ 124.00.

(for example the managers' team, a group of clients etc.) carry it out together.

The following are the research result analysis in the companies A and B.

system and the new proposed system. Table 8 shows, sparingly, these aspects.


Table 7. Proposed solutions for the hour meter redesign
