**4. Discussion**

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

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 in the core of the interventions.

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

#### **4.1 Company A**

Twelve aspects were identified for comparison of the final results between the current lock system and the new proposed system. Table 8 shows, sparingly, these aspects.

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 on the components number.

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, resulting in a total time of 220 minutes.

Beyond the manufacturing, the set assemble is also made by this supplier and the lock needs around 480 seconds to be ready for order. This service whole cost is of \$ 124.00.

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 of 68%) for the system assembling.

Integrating Reverse Engineering and Design for Manufacturing

cost of R\$ 35,000.00.

company), easy to used and resourceful.

once it suffers mostly axial strength.

the handle after been moved.

to much strength for moving.

and closing.

when a gap occurs, it is necessary to change the whole lock;

painful, once there is the necessity of forcing one of the edges;

and Assembly in Products Redesigns: Results of Two Action Research Studies in Brazil 209

 it is a complicate system for assembling and disassembling, due the presence of screw fly, spheres and springs, which can be used in a proper way for a lay person. Normally

 for being made through the union of a three-millimeter layers, generating a sixmillimeter cable, the squares end up being straight, which make the handling a bit

if the lock, after the opening, gets back to the vertical position, after closing the oven the

After the first tests with the new lock, it was possible to reach preliminary conclusions as to some difficulties: since it is a system in which the shaft/spring must tightly fit into the lock, it is necessary to focus on the door positioning, assuring a perfect alignment; if, due to the oven manufacturing, there is some dimension error, which happens very frequently (due to the existence of processes like punching, bending, fitting with no feedback and welding), it is necessary the use of washers for the correct positioning of the two-stage lock; as some of the proposed components will be machined, it is necessary some big initial investments for the manufacture of machining model, so much for metals as for plastic, in an approximately

On the other hand to these difficulties, it was possible to see the benefits of each lock. The current one has a robust system, which complies the market demands and it´s consolidated in the company. The new proposal is innovative (in relation to the models used in the

The current system is difficult to maintain, once the exchange of a component rarely solves the problem. Normally the system is substituted as whole, beyond the complexity of assembling and disassembling. The new lock is quite easy to assemble and disassemble, the major components can be exchanged with the removal of a screw. The system has less wear,

As for its functions, it is possible to observe in the current lock the following: to ensure the oven total sealing; provide relieve system, to serve as a stem for opening and closing of the oven. The new lock closing features include the functions of the current system and more: to open the oven with a twist of the handle, for the right or for the left; to assure a fast return of

With regard to the operation, there has been an improvement related to the opening, relieve

The current lock relieve system is considered to be inefficient, as it allows a very short distance for steam relieve, normally not noticeable by clients. The new lock relieve system allows a 20 mm relieve, and can be used with light touch on the handle. It cannot be driven by choice, in case the handle is activated and remains at 50 degrees of twist at the opening. The new lock allows the closing (lock) of the door, if it is moved with a light twist of the body when the operator is busy with his hands e doesn´t want to leave the oven door open. As for ergonomic, the current lock is considered by the team as a tough mechanism, needing

rotating component will crash on the panel and, quite probably, smash it.


Table 8. Lock project system final comparative results analysis

Through a Customer Service system and technical personal assistance one could identify some problems on the current lock:


208 Reverse Engineering – Recent Advances and Applications

**Requisite Before After** 

Maintenance Difficult, normally the system

Ergonomics Tough mechanism, handle

lever presses the set at every closing of the door;

There is no system to help spring returning movements.

considers it to be inefficient for steams release;

some problems on the current lock:

some components; leftover material (scrap);

tough;

Table 8. Lock project system final comparative results analysis

Functions 3 5

Number of

Time of system

Benefits

Operation

Time of manufacturing

Number of components 13 11

manufacturing processes 5 4

components (minutes) 220 20 Product costs (\$) 124.00 45.00

assembling (seconds) 480 150 Difficulties/Problems 7 3

> Robust system, meets the requirements like locks and consolidated in the company.

is changed as a whole.

medium strength.

great strength.

with straight edges.

OPENING: 90 degrees to the left, medium strength.

RELIEF: 45 degrees to the left,

Relief system Innefficient. It allows a 20 millimeter relief.

Through a Customer Service system and technical personal assistance one could identify

expensive manufacturing process, due to the amount and machining complexity of

over time or excessive handling, the system generates a gap caused by swear, once the

 for being a locking door system through friction between both parts, until they fit it´s necessary to force a bit to overcome that friction, which makes the system to be a bit

 The existing relief generates a very small opening between the door and the trim, which is not perceived by the client, so it is not used. It also can be used when the client

CLOSING: pressure on the door, 90 degrees to the right, Innovative lock, easy to use and good resources.

OPENING: 50 degrees to the left or to the right, maintains a

RELIEF: degrees to the left or to the right and release, small

CLOSING: light pressure or by

Lightweight mechanism, handle with rounded corners.

Easy assembling and disassembling.

small force.

door slam.

force.


After the first tests with the new lock, it was possible to reach preliminary conclusions as to some difficulties: since it is a system in which the shaft/spring must tightly fit into the lock, it is necessary to focus on the door positioning, assuring a perfect alignment; if, due to the oven manufacturing, there is some dimension error, which happens very frequently (due to the existence of processes like punching, bending, fitting with no feedback and welding), it is necessary the use of washers for the correct positioning of the two-stage lock; as some of the proposed components will be machined, it is necessary some big initial investments for the manufacture of machining model, so much for metals as for plastic, in an approximately cost of R\$ 35,000.00.

On the other hand to these difficulties, it was possible to see the benefits of each lock. The current one has a robust system, which complies the market demands and it´s consolidated in the company. The new proposal is innovative (in relation to the models used in the company), easy to used and resourceful.

The current system is difficult to maintain, once the exchange of a component rarely solves the problem. Normally the system is substituted as whole, beyond the complexity of assembling and disassembling. The new lock is quite easy to assemble and disassemble, the major components can be exchanged with the removal of a screw. The system has less wear, once it suffers mostly axial strength.

As for its functions, it is possible to observe in the current lock the following: to ensure the oven total sealing; provide relieve system, to serve as a stem for opening and closing of the oven. The new lock closing features include the functions of the current system and more: to open the oven with a twist of the handle, for the right or for the left; to assure a fast return of the handle after been moved.

With regard to the operation, there has been an improvement related to the opening, relieve and closing.

The current lock relieve system is considered to be inefficient, as it allows a very short distance for steam relieve, normally not noticeable by clients. The new lock relieve system allows a 20 mm relieve, and can be used with light touch on the handle. It cannot be driven by choice, in case the handle is activated and remains at 50 degrees of twist at the opening.

The new lock allows the closing (lock) of the door, if it is moved with a light twist of the body when the operator is busy with his hands e doesn´t want to leave the oven door open.

As for ergonomic, the current lock is considered by the team as a tough mechanism, needing to much strength for moving.

Integrating Reverse Engineering and Design for Manufacturing

structure).

model.

on the market.

possible in the current hourmeter.

competitors for sharing he market.

not only for the four proposal shown in Table 7.

contemplate in the scope of the accomplished work.

and Assembly in Products Redesigns: Results of Two Action Research Studies in Brazil 211

diminishing the components structure and improving their manufacturing planning. The passage of energy between the hour meter plate C1 and the terminal had to be made by two springs, internally assembled in their own accommodations in the mug. This assembling process is much faster than the previous one, beyond spring costs being inferior from the wire costs (including their cutting and preparation), as well as the insertion time to be

The **solution 2** provided mainly assembling ease of two sets. The welding process has been eliminated, taking advantage of the assembling concept through fitting of the reference product. However, the used concept in the solution proposal was different from the concept found in the reference product. In the proposal deep changes have been avoided in the components, to prevent the necessity of new models projects for the components injection. With the used concept, some small adjustments were enough in the existing models for the manufacturing of the new components. This proposed solution, beyond reducing the assembly time of these two sets, allows them to be disassembled at any time during the

The **solution 3** helped reduce the cost component, since the display no longer needs to be produced in aluminum, and the new component can be produced in galvanized steel, as was the support of the glass. In addition, the use of an adhesive to the display, eliminating the silk screen process and all the involved sub-processes (cleaning, painting and silk), reducing cost and assembling time. The new component reduces the number of components, as it brought together two components into only one (simplification of product

Finally, the **solution 4** was a natural result from previous ones, once it had been possible to propose only one mug as a wrapping and protection of the hour meter components. This solution simplifies the product structure, favoring a product standardization and reducing the failure possibility in the assembling because of the wrong mug for the right product

The proposed improvements will represent a significant reduction in the product several aspects and of its assembling/manufacturing process. Beyond, in case of testing failures, the hour meter can be disassembled and only those failing parts be exchanged, which is not

Beyond the improvement on the assembling time, the proposed solutions will allow a significant reduction in the hour meter cost-goal, allowing an increase of its competitiviness

Table 9 shows a general final summary of he benefits provided with a redesigned product,

Regarding the reduction of the product cost-goal, the analysis of the research team evaluates a reduction of 33%, providing opportunities to the company to compete with its direct

In the previous Company B product redesign final results analysis they were not taken into account the improvements made in the product electronics parts, once they were not

inferior from that necessary one for the wire welding of the other components.

assembly process, in the case of non-compliance in any of the other components.

The handle has straight corners, which can hurt with daily use. On the new lock the mechanism is light, it can be operated with a single finger; it is easy to be closed and it has rounded square to fit the hand.

After getting all the components in material resistant enough for testing the mechanism, there has been a meeting with all the responsible team for a test. Figure 9 shows the prototype ready for testing.

Fig. 9. New lock assembled for a test

With the use of a new door with proper drilling for the new lock, a mechanism has been assembled in the proposed oven and its operation can be tested.

All the team members handled the lock on different ways, according to their perceptions of the demands the new product must accomplish.

The new lock has been approved by everybody, as some accounts showed. The Major Cook stated: "it doesn´t make any difference for me the kind of lock; I like the current system, but the new one is really easier. The purchase responsible added: I liked it a lot, but now we must choose the materials, manufacturing processes and where it is going to be made. We are on the right path, the competitors are bringing on new things and this lock will be a difference for our oven". Finally, the Plant Director said: "the system is very cool. Let´s define if it is really accomplished in this prototype, to make more functional prototypes and testing. We can use pneumatic actuators to check the wears and go on adjusting till it can be introduced in our line".

#### **4.2 Company B**

The proposal of solutions, among those presented at Table 7, provided several benefits for the studied product at Company B.

The **solution 1** (see Table 7) provided the reduction of two components (wires) and their welding onto the adaptor. Previously the adaptor had distinct model for each hourmeter model. Such proposal allowed that only one of the existing models kept on being used, 210 Reverse Engineering – Recent Advances and Applications

The handle has straight corners, which can hurt with daily use. On the new lock the mechanism is light, it can be operated with a single finger; it is easy to be closed and it has

After getting all the components in material resistant enough for testing the mechanism, there has been a meeting with all the responsible team for a test. Figure 9 shows the

With the use of a new door with proper drilling for the new lock, a mechanism has been

All the team members handled the lock on different ways, according to their perceptions of

The new lock has been approved by everybody, as some accounts showed. The Major Cook stated: "it doesn´t make any difference for me the kind of lock; I like the current system, but the new one is really easier. The purchase responsible added: I liked it a lot, but now we must choose the materials, manufacturing processes and where it is going to be made. We are on the right path, the competitors are bringing on new things and this lock will be a difference for our oven". Finally, the Plant Director said: "the system is very cool. Let´s define if it is really accomplished in this prototype, to make more functional prototypes and testing. We can use pneumatic actuators to check the wears and go on adjusting till it can be

The proposal of solutions, among those presented at Table 7, provided several benefits for

The **solution 1** (see Table 7) provided the reduction of two components (wires) and their welding onto the adaptor. Previously the adaptor had distinct model for each hourmeter model. Such proposal allowed that only one of the existing models kept on being used,

assembled in the proposed oven and its operation can be tested.

rounded square to fit the hand.

prototype ready for testing.

Fig. 9. New lock assembled for a test

introduced in our line".

the studied product at Company B.

**4.2 Company B** 

the demands the new product must accomplish.

diminishing the components structure and improving their manufacturing planning. The passage of energy between the hour meter plate C1 and the terminal had to be made by two springs, internally assembled in their own accommodations in the mug. This assembling process is much faster than the previous one, beyond spring costs being inferior from the wire costs (including their cutting and preparation), as well as the insertion time to be inferior from that necessary one for the wire welding of the other components.

The **solution 2** provided mainly assembling ease of two sets. The welding process has been eliminated, taking advantage of the assembling concept through fitting of the reference product. However, the used concept in the solution proposal was different from the concept found in the reference product. In the proposal deep changes have been avoided in the components, to prevent the necessity of new models projects for the components injection. With the used concept, some small adjustments were enough in the existing models for the manufacturing of the new components. This proposed solution, beyond reducing the assembly time of these two sets, allows them to be disassembled at any time during the assembly process, in the case of non-compliance in any of the other components.

The **solution 3** helped reduce the cost component, since the display no longer needs to be produced in aluminum, and the new component can be produced in galvanized steel, as was the support of the glass. In addition, the use of an adhesive to the display, eliminating the silk screen process and all the involved sub-processes (cleaning, painting and silk), reducing cost and assembling time. The new component reduces the number of components, as it brought together two components into only one (simplification of product structure).

Finally, the **solution 4** was a natural result from previous ones, once it had been possible to propose only one mug as a wrapping and protection of the hour meter components. This solution simplifies the product structure, favoring a product standardization and reducing the failure possibility in the assembling because of the wrong mug for the right product model.

The proposed improvements will represent a significant reduction in the product several aspects and of its assembling/manufacturing process. Beyond, in case of testing failures, the hour meter can be disassembled and only those failing parts be exchanged, which is not possible in the current hourmeter.

Beyond the improvement on the assembling time, the proposed solutions will allow a significant reduction in the hour meter cost-goal, allowing an increase of its competitiviness on the market.

Table 9 shows a general final summary of he benefits provided with a redesigned product, not only for the four proposal shown in Table 7.

Regarding the reduction of the product cost-goal, the analysis of the research team evaluates a reduction of 33%, providing opportunities to the company to compete with its direct competitors for sharing he market.

In the previous Company B product redesign final results analysis they were not taken into account the improvements made in the product electronics parts, once they were not contemplate in the scope of the accomplished work.

Integrating Reverse Engineering and Design for Manufacturing

which allowed us to accomplish the current research.

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Table 9. Summary of the final results provided in the hour meter redesign
