STAGE 1

Evaluation and
Verification
The cycle begins
Contents

• Reverse Engineering Team Meeting

• Visual and Dimensional Inspection

• Discrepancy Review Versus Available Data

Example of Severe Component
Failure
• Quality Evaluation Report Generation

• Stage 1 Report Generation

• The Go/No-Go Decision

Starting with the component that has :
- the highest expected return on investment
- the highest likelihood of success, or
- the highest priority.
• All available technical data has been gathered and evaluated.
• Missing data and project type have been identified.
• Sample parts, both unused and failed, have been obtained.
Stage 1 is the most demanding part of the reverse engineering
process.
More actions must be taken in stage 1 than the other three stages

Preface
 Stage 1 Primary Steps are:

• Visual and dimensional inspection

Data Collection • review versus available data
• Failure analysis
• Quality evaluation report
Data Evaluation • Stage 1 report
• Go/no-go decision
Reverse Engineering Team Meeting

• The lead engineer collects all the data and samples in one
location and invites the project team members to participate in a
collaborative meeting.
• Having all this information available at the team meeting is
critical in order to make decisions regarding the direction this
project will take.
• Missing data in the team meeting can produce erroneous results
later in the process and may add unnecessary additional expenses
to the project.
Key design features to look for in evaluating any design are a
combination of any of the following:

Strength Reliability Wear

Corrosion Friction Processing
Utility Cost Safety
Weight Noise Styling
Shape Flexibility Size
Surface finish Control Stiffness
Lubrication Maintenance Volume
Stable artwork Specifications Obsolete parts
(for electronics)
Data
Collection Visual and Dimensional Inspection

• The visual inspection is simply a review of the overall condition

of the part in terms of reproducibility, quality, and its present
state of deterioration or wear.
• to assess where to begin the process of reverse engineering
including
1. the location of points of reference for machining,
2. key design elements and materials
3. notations on any special materials,
4. coatings,
5. tolerances, and so on.
Data
Collection Visual and Dimensional Inspection

• The dimensional inspection is a complete and accurate measure

of all component dimensions needed to fully characterize the
sample part and establish a configuration baseline.

defined by : conducted using

 size,  Calipers.
 shape,  Micrometers.
 weight,  Coordinate measuring machines, or any
 tolerances, other tool of measure.
 finishes, and other parameters.  Optical or laser tracking with probes which
automatically generate a digitized
computer model of the design
i. Comparison to Available Data
Data
Collection

dimensions
all shown in the
measurements
have been Comparison available
technical data.
taken
ii. Disassembly and Assembly Data

Procedures Collection

• While disassembling a component there should be a list

characterizing each piece and the order in which the pieces are
being disassembled.
• Additional design requirements such torque values or spring
compressions will need to be measured.
• Avoid destructive disassembly for inseparable assemblies
(components joined by welding, riveting, epoxy, or any permanent
bonding method.)
In most cases disassembly procedures are not available and must be
Data
constructed from scratch, or at least at the manufacturer factory Collection
vault.
great care must be paid for :
1. the need for a method to reassemble the component.
2. to develop technical information that heretofore did not exist
for posterity, as it were.
3. Provide some insight into the rationale for the original design.
Material Analysis Data
Collection

• Material must be analyzed before it can be identified.

• Material identification could be as simple as a metallurgical
analysis of a standard steel or as detailed as the identification of a
polymer coating or superalloy.
• Any variations between the material specified and the material
identified should be noted (performance improvement).
• The location of getting samples from the part is very important
• Material composition is one of the limiting factors considered in
the technical complexity evaluation
Operational Testing Data
Collection

• If operating samples are available that involve moving components

and unused samples from supply are also available, then
operational testing should be conducted for comparison
• Operational testing is conducted to establish the baseline
operating parameters for a component.
• The materials found during material identification should meet or
exceed the operating parameters.
• Safety factors are not always a matter of judgment. They can
often be a matter of legal codes and standards.
Data Discrepancy Review Versus
Collection
Available Data
The available data is reviewed for:
1. Available Data Adequacy: the available data must be reviewed
for both adequacy and completeness.
2. Major Discrepancies may fall into many categories like:
• variations between sample parts.
• variations from the sample parts to the drawing dimensions.
• material variations or substitutions.
These differences can be caused by:
Data
1. The original component may have been poorly machined. Collection
2. The equipment used to produce the original part may be
outdated.
3. Design changes may have occurred.
4. Poor documentation quality control or simply a drafting error
may be the reason.
Data
Collection Failure Analysis

• If failed parts are forwarded from the prescreen, then it may be

necessary to conduct a failure analysis.
• The failure analysis generally requires study of numerous samples for
correct identification of the major failure mode(s).
• it (they) may become the basis for recommending design changes.
• If approved, this analysis may be used as the basis for value engineering
in stage 2.
• Often included in failure statistics are
• components used during routine maintenance procedures, which are
thus
• more correctly characterized as replacement parts.
Data Quality Evaluation Report
Evaluation
Generation
• QER is a quantitative and subjective evaluation of the assembly,
machining, casting, materials, or other functional characteristics of the
component.
• To determine "quality“ of a part the following example questions may
need to be answered:
1. Does this part exhibit good construction?
2. Does this part match the available data? How closely?
3. Are any inappropriate parts evident?
4. Are the tolerances befitting the function of the part within the system which
it operates?
5. Does it do its job well?
6. Would I purchase this part for this application if the decision were mine to
make?
 item identification Data
Evaluation

quantification of the data availability

and discrepancies

summary of the failure analysis if one

was conducted.

Identification of the project type.

all the flaws in this component.

The recommendations requested can

be "continue“, or even “complex”
Data
Evaluation Stage 1 Report Generation

• includes key economic and logistics factors not considered QER

generation
• is the only document that the program decision makers will
probably use to make a go/no-go decision.
• The purpose of this separate report is to summarize all that is
known about this singular item to date.
a sample completed stage 1 report from a Data
program in existence in 1988. Evaluation
Empty sample stage 1 report Data
Evaluation

Section I & II are repetition of the

item identified in the QER.
Section III Production Cost Data
Estimates Evaluation

1. Current Purchase Price and Target Cost.

(Target = 75% Purchased)

2. Production Lot Sizes.

I. small lot of perhaps 1 to 10
II. annual lot quantity equal to the annual usage
III. economic lot quantity is the number of units that
would produce the lowest unit price without
manufacturing so many

3. The Should-Cost Estimate.

This should-cost estimate includes profit margins
added to the combined value of the individual
components and raw materials plus the cost of
assembly.
Section IV Reverse Engineering
Project Cost Estimates Data
Evaluation
The costs associated with the completion of stage 1
can be quantified, or closely estimated, for inclusion
in this report. It will typically cost $1000 or $2000 to
a few ten thousands of dollars
The costs to complete stages 2, 3, and 4 can be
estimated using a breakdown structure based on the
following task costs:
• Configuration determination
• Development of drawings
• Development of part list
• Material determination
• Cost to fabricate prototype(s)
• Establishing testing and/or performance specifications
• Possible destruction of sample part(s)
• Management and logistics support for reverse
engineering
Section V Risk Assessment
This is simply a general engineering judgment of Data
whether there is enough potential for a return on Evaluation
the investment

Section V Overall Recommendation

First, it must be determined whether the available
technical data is adequate and if they are to be used in
their present state to fabricate future spare parts.

Second, it must be determined whether it is economical

to proceed to stage 2.
The recommendations will usually fall into the categories
of compete, low priority, terminate, or proceed to stage 2