Reverse Engineering For Beginners
Uploaded by
Sunil RaithathaReverse Engineering For Beginners
Uploaded by
Sunil RaithathaReverse
Engineering
For Beginners
By
Sunil Raithatha
Thanks
I thank you very much for giving me
this opportunity to present before
you
Reverse Engineering for Beginners.
Goal Of Presentation
To let you know RE and Methodology
for Reverse Engineering a Product.
Overview
● Reverse Engineering Importance.
● Reverse Engineering Introduction.
● Methodology.
● Resources.
Why You Should be Interested
● Most of the time Product Development is lengthy and not
going as predicted or expected.
● Time to Market is High.
● Too Much Trial and Error.
● Jugad Approach.
● Cost Overrun.
● Death of Product before it is Born.
Reverse Engineering Importance
Post CoVid-19 India need to develop many Import Substitute Products.
Post CoVid-19 India needs to Boost Make In India
Power Of
RE
Systematic RE is need of the
hour.
Post CoVid-19 need of Country
• As Global Supply Chain is getting realign post CoVid.
• Need to Quickly develop new product and Serve active Gap
created.
• China has developed intellectual infrastructure for Reverse
Engineering.
• Reverse Engineering is Science. (Copying a Product is JUGAD)
• RE generates lot of Data and Learning. Useful to reconstruct and
re design product.
Reverse Engineering Definition:
Reverse Engineering also called Back Engineering,
is the processes of extracting design information or
know how from already successful or existing
product and reproducing it based on extracted
information.
Product / Software / Part
Reclamation.
Examples of Reverse Engineering
The Tupolev Tu-4 is a piston-
engined Soviet strategic
bomber that served the Soviet
Air Force from the late 1940s
to mid-1960s. It was reverse-
engineered from the American
Boeing B-29 Superfortress.
Examples of Reverse Engineering
Very Good RE work is done in
Automotive Industry to
develop new models Reverse
Engineered and Improved for
Indian Condition.
Examples of Reverse Engineering
Household Appliances offers
very good opportunity to
practice Reverse Engineering.
Methodology or Process
● Preliminary Cost Analysis.
○ To estimate cost of Raw Material
○ To estimate Approximate Production Cost.
○ To ascertain availability of Manufacturing Capabilities.
○ Purpose of this exercise is to DO or NOT to Do decision.
○ This step is avoided when Market Gap is evident and high.
● Detailed Reverse Engineering.
Reverse Engineering Process.
Capture
Specification Creating CAD Process
Production
Performance Model Sheets
Data
Testing &
BOM Capture Benchmarkin
Prototype
Creation Legacy Data g
Reverse Engineering is Fastest Way
of Learning Engineering and Moving
Forward.
Capturing Specifications & Performance Data:
● Specification Sheet of Product if available.
● Use Product and note Performance Data.
● Generate User feedback.
● Note Changes to be made for Local Market.
● Note Improvements targeted.
● Keep Original Sample for BenchMarking with newly developed product.
Create Detailed Bill Of Materials:
● Remove Product from Packing. Make Bill of Packing Material.
● Dismantle Product and Make List of Items.
● Make Estimated Bill of Material.
● Group BOM as Manufactured , Bought Out Items & Packing Items.
● Give Name to Each Part.
● Make Note of Material, Weight and Numbers Required.
● Make Note of Process of Manufacturing.
● Estimate Cost of Each Item.
● Estimate Cost of Production, Ball Pass figure.
Create Detailed Bill Of Materials:
Part No. Name Material Size Remark
SS001 Outer Body PP 250x150x50 Injection
Moulded
SS002
SS003
Capture Legacy Data
● Use Precision measuring techniques.
● CMM also can be used.
● Capture all the features on each component.
● Capture Surface Finish, Surface Treatment etc.
● Use 3D Scanner to generate cloud data for surfaces.
● Capture Data & Specifications of all bought out items.
● Capture legacy data for Packing Materials.
Technology for Capturing Data
● CMM
Technology for Capturing Data
● 3 D Scanner
Creating 3 D Model
Process Sheet Making.
● Machined Parts.
● Plastic Parts.
● Sheet Metal Parts.
● Forged Parts.
● Casted Parts.
● Die Casted Parts.
You need to Collaborate with Expert from
different discipline.
Process Sheet Making.
• Most important part of Reverse
Engineering.
• Experts from different stream to
be roped in. Vendor Support.
• Capital Investment and Cost of
Production to be kept in mind.
Development by
Collaboration
Prototype Making.
• Use of Rapid
Prototyping.
• CNC Parts Making.
• Laser Cutting.
• 3 D Printing.
Testing & Benchmarking
• In House testing.
• Consumer Experience
Feedback.
• Generating Actionable
Feedback for Design and
Production People.
Redesign Products or Parts
● Based on testing results / Customer feedback.
● Tweek some of the design features or Part design.
● Make New Prototype.
● Test and Benchmark again.
Plan Production Toolings
● Plan Production toolings and Production.
● Make Record of Every Data Generated during RE Process.
Importance of Data Generated in RE
• Accuracy of Data reduces Risk of Failures.
• Better Understanding of Engineering behind
delivering customer experience. Without
• New Ideas to generate New USP. Engineering
• Possibility of IP protection. Data
• Ease of Collaboration with Supply Chain. It’s JUGAD
• It’s lays foundation for future improvement.
Successful Manufacturing &
Marketing:
● Reverse Engineering is Scientific Way of
reducing Development time and resources.
Local Needs & Local Supply Chain:
● Post CoVid Supply Chains will tend to be
localized.
● Understanding Local Needs will give
competitive advantage.
Reverse Engineering is Need of
Country :
Power Of
RE
Any Questions
