Product Teardown.pptx

Product Teardown

1. PRODUCT TEARDOWN Product Development and Reverse Engineering Dr P Nallasamy Mech -PSG TECH 1

2. Product Teardown The process of taking apart a product to understand how it is made and how it works A product teardown process is a formal approach to learning about and modeling the functional behavior and physical components of a product 2

3. Product teardown Example: Scanner 3

4. Product teardown Example: Hot Glue Gun 4

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7. Drum brake or internal expanding brake 7

8. Primary purposes Dissection and analysis during Reverse Engg Competitive benchmarking Experience and knowledge 8

9. Dissection and Analysis Evaluate the current status of a product Understand the current technology, functions, and components Identify strengths, weaknesses, and opportunities for new products 9

10. Competitive Benchmarking Establish a baseline in terms of understanding and representation of the competition The baseline provides a comparison for new conceptual designs . 10

11. Experience and Knowledge Grow engineering knowledge from which to draw in new concept development Provide the basis for transferring solutions to analogous problems 11

12. Teardown Process (5-steps) 1.List the Design Issues 2.Prepare for Teardown 3.Examine Distribution and Installation 4.Disassemble, Measure, and Analyze 5.Create Data Sheets and Models (Bill of Materials) 12

13. Step 1: List the Design Issues Identify the purpose of the teardown Determine what models should result from this process Create a data sheet in which all information can be captured 13

14. Step 1: Continued What are the problems and opportunities that the design team facing? New project Not all design issues are known Investigate the customer requirements and competitors products Re-design What was difficult? What problems were solved? What are the related technologies? 14

15. Step 1: continued Customer needs Product functionality Information includes Component names Quantity of parts Dimensions Material Weight Manufacturing process Primary functions Cost 15

16. Step 2: Prepare for Teardown Gather tools that are needed for: 1. Disassembly Screw drivers 2. Process Documentation Camera Video tape Multi-meter Flow meter 16

17. Step 3: Examine Distribution and Installation How to acquire parts? How to distribute and market the product? How is the product packaged? What is involved in installation? Examine consumer installation instructions and procedures for costs, effectiveness, and liability 17

18. Step 4: Disassemble, Measure, and Analyze Take pictures of the product Run, analyze and measure the product Coordinate disassembly with measurement, experimentation, and modeling Avoid destructive disassembly 18

19. Step 4: Continued Take apart the product Take pictures of each component and major assembly Take measurements to complete data sheet Be sure that all data models and pictures are referenced in the data sheet 19

20. Step 5: Create Data Sheets and Models Exploded View Photos documenting product assembly Geometric models Bill of Materials (BOM) A written form detailing the product’s components The data collected in BOM are required for analyzes (including cost and performance) 20

21. Step 5: Continued Functional models Focus on what it does not how it does it. Demonstrate the product’s transformation and of materials, information, and energy from an input state into the desired functions Force flow diagrams Track the movement of forces through a product Provide opportunities for component combinations to improve product 21

22. Exploded View 22

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24. BOM Example 24

25. Functional Model - Example 25

26. Reverse Engineering: Force Flow (Energy Flow) Diagrams 26 Example of a FFD for a paperclip

27. Teardown Methods Functional Modeling Subtract & Operate Procedure (SOP) 27

28. Subtract & Operate Procedure (SOP) 28 The functional behavior of a product can be deduced and modeled through the subtract and operate procedure Functional modeling provides a formal approach to beginning concept development by directly translating customer needs into desired product behavior.

29. SOP By first developing product function, the gap between customer needs and product form is lessened Modeling the function of existing designs is useful in learning about competing products, gathering ideas for new products, and learning about functional modeling . 29

30. S&O Procedure 1. Remove one component from the product When less detail is needed, a collection of parts or an assembly can be removed. 2. Operate the product Either mentally or physically operate the product. Keep in mind the user requirements for the product and ensure that they are all exercised. 30

31. 3. Analyze the effect and deduce function of the missing component Ask why and how the product is not longer functioning properly. Through either visual or experimental means (if necessary), form specific statement of the component function. Multiple components may have the same function or serve multiple functions. A helpful form of the statement of function is to provide a verb-noun phrase. The verb is the function performed and the noun is the material, energy, or information being acted upon. Examples: rotate shaft, support motor, translate glue, convert electricity to rotation 31

32. 4. Replace the component and repeat for each component 5. Compose a model of product function by combining the discovered subfunctions The result of the subtract and operate procedure is a collection of product subfunctions . Forming a coherent model of the complete product adds ensures that the system and subassembly interfaces are understood. Two aggregate models are the function tree and function structure 32

33. Example 33

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35. The function tree structure is an organization of the functions derived from the subtract and operate procedure. The function tree mirrors the physical assembly in terms of structure and decomposition where the assembly now provides higher level functionality 35

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38. Functional Model 38

39. Force Flow (Energy Flow) Diagrams 39 Another useful method to determine how a product operates, and the purpose of its sub-components, is to create a Force Flow Diagram Force Flow Diagrams are a systematic way to help you determine combination between components and their interaction FFDs represent the transfer of force through a product’s components

40. How to create a FFD The components are symbolized as nodes using circles. The component name appears in the circle. The forces are drawn as arrows connecting the components in which the force transfer takes place. More that one arrow can enter or terminate into a node. 40

41. Example of a FFD for a Stapler 41

42. Stapler is dis -assembled, and all constituent part are illustrated 42

43. FFD for a Stapler 43

44. Teardown Example: Hot Glue Gun 44

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50. Product with ruler 50

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52. Exploded Image 52

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54. Trigger Assembly 54

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56. Heating Element 56

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58. Guide and Metal Part 58

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60. Single level BOM 60

61. Indented BOM 61

62. Indented Modular/Descriptive BOM 62

63. Product Function Model 63

64. Mini-Project - 1 Product Teardown analysis Disassembly Exploded view Bill of Materials Functional Model Force Flow Diagram 64