A reverse engineering process for mechanical engineering systems

Rochester Institute of Technology

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2-1-2007

A reverse engineering process for mechanical

engineering systems

Frank Tamarez-Gomez

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Recommended Citation

A REVERSE ENGINEERING PROCESS FOR

. MECHANICAL ENGINEERING SYSTEMS

By

Approved by:

Frank B. Tamarez G.

A Thesis Submitted

m

Partial Fulfillment

of the

Requirements for the

MASTER OF SCIENCE

In

MECHANICAL ENGINEERING

Edward Hensel, Ph.D.

Department of Mechanical Engineering

(Thesis Advisor)

Alan Nye, Ph.D.

Department of Mechanical Engineering

(Department Representative)

Elizabeth DeBartolo, Ph.D.

Department of Mechanical Engineering

Marcos Esterman, Ph.D.

Department of Industrial

&

System Engineering

George Slack, MS

Department of Electrical Engineering

Department of Mechanical Engineering

Kate Gleason College of Engineering

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Acknowledgments

I wouldliketoexpress_myextreme gratitudetoallthepersons whoassistedme

withthe thesisand providethe_necessarysupportfor itscompletion: Dr. Edward_Hensel,

mythesis advisor, forbeingvery patient, encouraging,understanding, supporting and a

friend fortheguidance ofinthe_writingofthis thesisinthepasttwo years. Hehasbeen

likeafatherindifficultand smooth_times,withoutthe_helpofDr. _{Hensel,I may}never

have completedthe thesis. Dr. Elizabeth_DeBartolo,Dr. Marcos Esterman Dr. Alan Nye

andMS. George Slackfor_providingprofessional andpersonalguidancethat_greatly

enhanced and prepared_mymindand_abilitytofocusonthis thesis and assistanceto_help

minimizethestressof_learningnewthings. _Furthermore, Iwouldliketo express_my

deepestgratitudeto_{mygirlfriend,} Lori_Rosario, for her_love,patience,understandingand

supportthatalways wastherewhen needed. Iexpress an_overwhelmingappreciationto

myparents,Francisco and_Ana, foralways_beingtherewhenIneeded supportand your

numerous sacrificesextended farbeyondthedutiesof_parents,aswellas _friends, and I

loveandthankyou. _Finally,I wouldliketo thankGodfor_beingbesidemeallthe times

Table of_Content

ACKNOWLEDGMENTS 1

TABLEOF CONTENT 2

LISTOFFIGURES 9

LISTOFTABLES 17

ABSTRACT 19

CHAPTER 2 LITERATURE REVIEW 31

2.1 ApplicationofReverse Engineering MethodsinBusiness 32

2.2 ApplicationofReverseEngineering MethodsinSoftware 36

2.3 ApplicationofReverse Engineering MethodsinMechanicalComponents 48

2.4 ApplicationofReverse EngineeringMethodsforMechatronics 53

2.5 ApplicationofReverseEngineering MethodsinIndustrial Engineeringand

Miscellaneous 57

2.5Literature ReviewSummary 66

CHAPTER 3.0REVERSE ENGINEERING PROCESS FOR MECHANICAL ENGINEERING

SYSTEMS_(REPMES,) 67

3.1 Management_Decision,selecta product forREand definegoals 71

3.2CompetitiveBenchmarking 71

3.3 Needassessment 72

3.4Establishing Engineering Specifications 74

3.5 SelectProductstoRE 76

3.6Replace Lost Technical Data Package 78

3.7Knowledge Expansion 79

3.9 GettingtheProduct_(s)forRE 82

3.10GettingProductDocumentation 83

3.11 Design Team SelectionandREplan 84

3. 12 Product Functionality 86

3.13Visualinspection oftheproduct and understandhow itoperates 87

3.14DesignFeature 90

3.15ElectricalFeature 91

3. 16Mechanical Feature 92

3.17TechnicalImplementation 93

3.18Critical Analysis 95

3.19 Validation 96

3.20 Designverification 98

3.21 ProcessStateEstimation"Inconsistency"

99

CHAPTER4CASE STUDY:REPMES,APPLIED TO A FLASHLIGHT 100

4.1 ManagementDecision 101

4.2Competitive BenchmarkingandProduct Improvement 102

4.2.1Needassessment 102

4.2.2Establish_EngineeringSpecifications 103

4.2.3SelectnProductsforReverse_Engineering 103

4.3ReverseEngineering Sub-Objectives 104

4.4Acquirethe_Product(s)forReverse Engineering 104

4.5Get Product Documentation 105

4.6Design TeamSelection 106

4.7Product Functionality 106

4.8Visualinspectionofthe product and understand how it operates 107 4.8.1_Inspection,Dissection, andBill ofMaterials 707

4.11 Mechanical Features 112

4.12 MaterialProperties 112

4. 13 Critical Analysis 112

4.13.1_AssemblyAnalysis 112

4.13.2 MechanicalAnalysis 113

4.13.3 Material PropertiesAnalysis 114

4.14 Technical Data Packagefor theV2D-B Flashlight 116

4.15 Case Study Summary 118

CHAPTER5 REVISIONSOFREPMES,TO IMPLEMENTREPMES2 119

CompetitiveBenchmarking 119

ReplaceLost Technical DataPackage_(TDP)andKnowledge Expansion 120

TechnicalDataPackage 125

CHAPTER 6IMPLEMENTED REVERSE ENGINEERING PROCESS FOR MECHANICAL

ENGINEERINGSYSTEM_(REPMES2)TO TORQUE CONVERTER"FORD"

128

6.0Management_Decision,selecta product forREand definegoals 129

6.1 ProductSelectionbasedoneconomic factors 130

6.2 Acquirethe_Product(s)forReverse Engineering 134

6.3 Design Team Selection 134

6.4 Reverse Engineering Plan 135

6.5 GetProduct Documentation 136

6.6Product Functionality 136

6.7 Dissecttheproductandunderstand how it operates 137

6.7.1Inspection 137

6.8Designfeature 139

6.9Technical Implementation (Designfeature) 140

6. 10 Criticalanalysisoftorqueconverter(DesignFeature) 141

6.11 ElectricalFeature 144

6. 12MechanicalFeature 144

6. 13 Critical Analysis (Mechanical_Feature) 145

6.14 MaterialProperties 146

6. 15 Criticalanalysis(Material_Property) 147

6.16 Technical Data PackagefortheTorque Converter"Ford"

149

6. 17Case Study Summary 152

CHAPTER 7 REVISIONSOFREPMES2TO FINAL REPMES 153

CHAPTER 8 CONCLUSION 156

CHAPTER 9 RECOMMENDATION FORFUTUREDEVELOPMENTS 157

REFERENCES 158

APPENDKA: EXPLANATION TOOLS 164

A.l Stepsfor thecreation ofthe"HouseofQuality" 164

A.2 DeterminingtheRoot Cause: 5 Whys 168

A.3 FASTMethod 170

A.4 Howtocreatea precedent result diagram"IshikawaDiagram"

171

APPENDKB: REVERSE ENGINEERINGREPORT AND TECHNICAL DATA PACKAGE

FOR THE RAYOVAC FLASHLIGHT V2D-B 173

B.i Title Page 175

B.n ExecutiveSummary 176

B.m Reverse Engineering ObjectivesandStatementofWork 177

B.I Introduction 177

B.2 Product DissectionandInspection Report 177

a. Product inspection 177

b. _GatheringBasic Information 178

d. Photographic Bill_ofMaterials 779

e. AssignmentofNamesandNumberstoPartsandSubassemblies 184

B.4. Design Analysis ₁₈₉

a. UserNeedsAssessment. 189

b. Competitive_{Benchmarking 207}

B.5 Mechanicalfeaturesanalysis ₂₀₃

B.6. Electrical FeaturesAnalysis 204

a. Schematicdiagrams. 204

b. Circuitsimulations ₂₀₅

c. Component Specification 205

B.7 MaterialpropertiesFeaturesAnalysis 206

B.8 System FunctionalityAnalysis 206

a. SetMode 206

b. _Identifyingtheroot cause_usingtheFive Whys 207

c. FAST Diagram MethodfortheFlashlight V2D-B 208

d. Function TreefortheFlashlightV2D-B "Rayovac"

210

e. _{Black Box of}theFlashlight V2D-B 277

B.9 Final Technical Data Packagefor theDevice 213

a. 3-D Solid Model_oftheDevice 275

b. 2-DDrawingPackage 27<5

B.ll. Extrainformation 229

APPENDK C REVERSE ENGINEERING REPORT AND TECHNICAL DATA PACKAGE

FOR THE FORD TORQUE CONVERTER 239

C.i Title Page 241

C.n Executive Summary 242

Cm Reverse Engineering ObjectivesandStatementofWork 243

C.3. ProductDissectionandInspection Report 247

a. Productinspection

..247

b. _GatheringBasicinformation ..249

c. _{Mass of}torqueconvertercomponents ..249

d. Photographic_{Bill of}Materials ₂₅₀

C.4. Torque Converter Functionality ₂₅₄

a. Eventprocess chaindiagram ₂₅₄

b. _Identifyingtheroot cause_usingtheFive Whys ₂₅₅

d. FunctiontreefortheTorqueConverter ₂₆₀

e. BlackBoxanalysisfortheTorque Converter. 261

C.5. Design FeaturesAnalysis 263

a. Mathematical_{modeling of}theTorque ConverterandFluidCoupling. 263

b. _Analyzingthe torqueconverterinterms_offluidand clutchfriction 277

c. Criticalanalisysdesignfeatures 273

C.6. MechanicalFeaturesAnalysis 280

a. Operations ₂₈₀

b. Multiplication 283

C.7. Electrical FeaturesAnalysis 285

C.8. MaterialsProperties Features Analysis 285

a. RockwellHardness 285

b. Brinell Hardness 287

c. _{Metallography} 290

d. ResearchandComparisons 293

e. Analysis_ofvolumefraction_byimage 298

f Criticalanalysisfor narrowing downoptions 300

C.9. Final Technical Data Packagefor theDevice 304

a. 3-D Solid Modelofthedevicecreated_{using Pro-E Wildfire}2.0 304

CIO. Extrainformation 324

a. Graph_ofCruisingspeed. 324

b. Fluid_Coupling 325

APPENDK D: FINAL REVERSEENGINEERING PROCESSFOR MECHANICAL

List of_Figures

Figure 1Engineering_{students learn through studying examples ofdesigned systems 21}

Figure2Reverse_{engineering requires testing and investigation of productsunder}

investigation.Cartoontaken from ₂₂

Figure 3 Drawingofa"lowerreceivingtube"

takenfrom aTechnicalData Package [7].23

Figure 4 Lexus

-phototakenfromcontent source ₂₆

Figure 5Apollo Rocketfrom the1960'sleaving theNASAheadquarters 27

Figure 6 SolenoidValvesmanufactured by theG.W.Lisk Companyfor applications such

as_{vehicle, aerospace, marine,}etc ₂₈

Figure 7 Formanalysis andProcess Model_Generation,inspired byKim 33

Figure8 Event ProcessChainDiagramfromKim 34

Figure 9 REas a tool for product_planning,inspired bySchumacher 36

Figure 10 Processcontrolsteps for_RE,inspired byHildreth 38

Figure 11 ExampleofProcesscontrol stepfor_RE,whereLSLandULSare the limits set

TO BE INCONTROL 40

Figure12REprocess and documentation for software_system,inspired byAbbattista....41

Figure 13 REprocess by applying object-oriented frame working to understand the

CONCEPT OFTHEDOMAIN,INSPIRED BYJ-M DeBAUD 43

Figure14 Synchronizedrefinementsin order to implementdesign,inspired byJ-M DeBaud

43

Figure 15 CharacterizingandevaluatingREprocess_components,inspired byTortorella

Figure16 REMethodologyto_{reconstruct data flowdiagrams,}inspired byBenedusi 46

Figure17REstepstoanalyzedata for_software,inspired byMuller 47

Figure 20Reverseengineering of mechanicalcomponentsforCAM /_CAD,inspiredby

Kalra 49

Figure21 REtogenerate a solid model using_CAD,inspiredby byGirishPhansalkarand

Rajesh N.Dave 51

Figure 22 Reverseengineeringand re-engineering of avionicslegacy_components,

inspired byRiffle 55

Figure23Stepsfor reverse engineering as anapproachto studying_{Mechatronics,}

INSPntED bySaleh 56

Figure24Preliminaryplan for reverse engineering techniques forRe-Plenishmentof a

Spares Breakoutprogram,inspdjedbyDiMascio 59

Figure25Reverse Engineeringand redesign accord toOtto 60

Figure26_{Investigation,}prediction,and hypothesis tools for_RE,takenfromOtto 61

Figure27 ConcreteExperience:Function & Form- _{tools for}

RE,taken fromOtto 61

Figure28Fourprocessstages for reverse engineering byIngle 63

Figure29Fivesteps to productdevelopment,OttoandWood 65

Figure 30 Apyramid illustrating therelationshipsand flow ofinformationbetween

engineering, re-engineering,andreverse engineering 67

Figure 31 Preliminaryphases ofREPMES1aspresentedin the original thesis proposal...70

Figure 32 Laterphaseof REPMES1aspresentedinthe original thesis proposal 70

Figure 33 Need assessment, Kevin OttoandKristin Wood 73

Figure 34 EngineeringSpecifications,Kevin OttoandKristinWood 75

Figure37 GettingtheProduct_(s)forRE 82

Figure38 Getting Product Documentation 83

Figure39 Design Team Selection ₈₅

Figure 40 REplanlayout ₈₆

Figure 41 Product_{Functionality,}KevinOttoandKristinWood 87

Figure42 Visual inspections,KevinOttoandKristinWood 89

Figure43Design Features 90

Figure 44ElectricalFeature 92

Figure45 MechanicalFeature 93

Figure 46 TechnicalImplementation 94

Figure47 Critical Analysis 96

Figure 48_Validation,Riffle 97

Figure 49 Designverification 98

Figure 50 ProcessStateEstimation 99

Figure 51 Rayovac Flashlight Model V2D-Bused inCase Study 101

Figure 52 Electronicallyregulated,variableoutputLEDflashlight 106

Figure 53Sampleinspection form to be used by the inspector during dissection.

Additionaldetablsarepresented in theAppendixB 109

Figure54the2DdrawingoftheBaseoftheFlashlight V2D-B 110

Figure55ElectricalCmcurrof theFlashlight V2D-B "Rayovac Ill

Figure 56 Assemblyview of the solid modelflashlight 113

Figure 573Dmodelof theflashlight basecreated usingPro-Ewildfdie2.0 114

Figure59aREPMES2-_{Revised Process}

123

Figure60Final_{Complete Technical Data Package 127}

Figure61 Sampleprojectselectionrecommendationsheetto be used by the design team

duringEconomicanalysis.Additionaldetails are presentedinAppendix C 131

Figure62ReturnonInvestment_{(ROI)equation,}takenfrom_[39] 132

Figure63 Exampleinspection form for theTorqueConverter 138

Figure 64 Pro-EdrawingofImpellercase ₁₄₀

Figure65Vehicledisplayoflocation forTorqueConverter 141

Figure663DmodeloftheTorque Converter 142

Figure67 Actualpictureofthe torqueconverterImpellershowing the guide rings and

its fins 142

Figure68

-Mathematicalequationsofthree components of the torqueconverter 143

Figure 69Statorsthreecomponents 145

Figure 70 ExplodedviewoftheTorqueConverterthat shows all parts andcomponents

145

Figure 71 Fluidflows in the torqueconverter 146

Figure 72 DistanceversusHardnessGraphforTorque Converter'simpellercase 148

Figure73 PublishedgraphforDistanceversusHardnessGraph 149

Figure 74- REPMES_materialProperty Process 154

Figure A.1 QFDRepresentation,inspiredbyKevin OttoandKristin Wood 165

Figure A.2 FASTMethod,iNSPntED byKevin OttoandKristinWood 171

Figure A.3 IshikawaDiagram,taken fromAnswers.com 172

Figure B.2 Ishikawa Diagramor_{"Assembly Precedence}Diagram"

forFlashlight Model

V2D-B 181

Figure B.3 ExplodedviewforFlashlight V2D-Bwith correspondingfeatureandpart

numbers ₁₈₄

Figure B.4 AnkurAbrollike/dislike survey 190

FigureB.5Lori Rosariolike/dislike survey 191

FigureB.6 Juan M.Garcialike/dislike survey 191

Figure B.7 Stephanie Pntolike/dislikesurvey 192

Figure B.8 LoriRosario Questionnairemethod 193

FigureB.9 Ankur AbrolQuestionnairemethod 194

Figure B.10Stephanie Pmo Questionnadxemethod 195

Figure B.ll Juan M.Garcia Questionnadiemethod 195

Figure B.12SchematicdiagramoftheFlashlight V2D-B 204

Figure B.13 FASTdiagram for theFlashlightV2D-B,inspired byKevinOttoandKristin

Wood_[40] 210

Figure B.14Functiontree for theFlashlight V2D-B"Rayovac" ₂₁₁

FigureB.15Black BoxfortheFlashlightV2D-B 212

Figure B.16 Black Boxfor theFlashlight V2D-B 212

Figure B.17 Refinedfunction structure for theFlashlightV2D-B 213

Figure B.18 Back ExplodedviewoftheFlashlight V2D-B"Rayovac" 214

Figure B.19 Complete Assembly-DefaultviewoftheFlashlight V2D-B

"Rayovac"

214

Figure B.20 Complete Assembly-Top ViewoftheFlashlightV2D-B

"Rayovac"

FigureB.21 Complete SecondaryAssembly-Default

view oftheFlashlight V2D-B

"Rayovac"

214

Figure B.22CompleteSecondaryAssembly-Default

sideviewoftheFlashlight V2D-B

"Rayovac"

215

FigureB.23 DissembledviewoftheFlashlightV2D-B "Rayovac 215

Figure B.24CompletetransparentviewoftheFlashlight V2D-B "Rayovac 215

FigureB.25 Flashlight V2D-B Base 217

FigureB.26 Flashlight D BatterySupportPole 218

FigureB.27 Flashlight Water Protector Washer 219

Figure B.29 FlashlightCopperPole 221

Figure B.30 Flashlight Bulb Base 222

Figure B.31 Flashlight V2d-B Switch 223

Figure B.32 Flashlight Bulb "Mag 4Cell" 224

Figure B.33 Flashlight Lightcover 225

Figure B.34 Flashlight V2D-BSpring 226

FigureB.35 FlashlightConvexLens 227

FigureB.36 Flashlight Hand Band 228

Figure B.37 Component Formfor theFlashlight V2D-B 229

Figure B.38 Component Formfor theBulboftheFlashlight V2D-B 231

Figure B.39 Component Formfor theLightreflectorsof theFlashlight V2D-B 232

Figure B.40 Component Formfor theCurrentflow deviceof theFlashlightV2D-B 233

Figure B.41 Component Formfor thelightraypointerof theFlashlightV2D-B 234

Figure B.43 Component FormfortheSpkalspring andALpoleof theFlashlightV2D-B

236

FigureB.44Component Form_{for the light cover of theFlashlightV2D-B 237}

Figure B.45 ComponentForm_{for the copper pole and switchof theFlashlight V2D-B} ..238

FigureD.IaREPMESi-_{Revised Process}

...329

FigureD.IBREPMES2-_{Revisedprocess continued}

330

FigureD.2REPMES2-_{Complete Technical Data Package}

331

FigureD.3_{Need assessment, Kevin Otto}andKristinWood 332

FigureD.4Engineering_{Specifications,}KevinOttoandKristin Wood 332

Figure D.5SelectnProductto reverse ₃₃₃

FigureD.6Stepstoward product selection 334

Figure D.7RE_{sub-objective(s) 335}

FigureD.8GettingtheProduct_(s)forRE 336

FigureD.9Getting Product Documentation 336

FigureD.10DesignTeamSelection 337

FigureD.ll Design TeamSelection 338

Figure D.12 Product_{Functionality,}Kevin OttoandKristin Wood 339

Figured.13 Visual_inspections,KevinOttoandKristinWood 340

Figured.14 Design Features 341

FigureD.15 ElectricalFeature 342

Figure D.16 Mechanical Feature 342

Figure D.17 Technical Implementation 343

Figured.19_Valdjation,inspiredbyRiffle 345

Figure D.10 Designverification 346

Figure D.21 ProcessState Estimation 346

Listof_Tables

Table 4.1_REPMESiCaseStudy Task Breakdownlocation 100

Table4. 2Design TeamCore Membership EngineeringFunctionsfor theFlashlight V2D-B

106

Table4. 3ElectricalfeatureFlashlight V2D-Bat1 Meter Ill

Table 6.01.Reverseengineeringplanschedule andlocation 129

Table B.IMassofPartsin theProduct 179

Table B.2 Photographic BnxofMaterialof theFlashlight V2D-B 182

Table B.3 Summationimportance of the questionnaire method 196

Table B.4 Priorityofcustomer needs 198

Table B.5 Priorityofdesign level 199

Table B.6 Priorityofergonomics 200

TableB.7 Competitive Companiesanddescriptions 201

Table B.8 Competitiveproductanddescription 202

Table B.9-Quality FunctionDeployment(QFD)/ HouseofQuality Matrk 203

Table B.10 ElectricalfeatureFlashlight V2D-Bat1 Meter 205

Table B.ll SchematicsforFlashlightV2D-BONorOFFmode 207

Table CI Individualpartsweight 249

Table C.2 Torqueconverter total weight 249

Table C.3 BillofMaterialsfor theTorqueConverter"Impeller

Assembly"

252

Table C.4 Billof Materialsfor theTorque Converter "Turbine

Assembly"

252

TableC.5Billof Materialsfor theTorqueConverter "Stator

assembly"

Table C.6BillofMaterialsfor theTorque Converter"TCClutch"

253

TableC.7 BillofMaterialsfor theTorqueConverter"TCBase"

254

TableC.8Rockwell Hardnessvalues for theimpellerand the turbine 287

TableC.9- BrinellHardness_testresults 290

Table CIO- Chemical_{composition of}Alloy_steel

andcarbonsteel,taken from_[54] 302

Abstract

Thisthesispresents a_{literaturereviewofcurrent reverse}

engineeringtechnologies

and_processes,with an emphasis ontools_commonlyusedin SoftwareReverse

Engineering(SRE). _Usingthe foundationoftheliterature_{review, the thesis}willthen

propose a standard_process,referredtoas "AReverse_EngineeringProcessfor

Mechanical_EngineeringSystems(REPMES)."

The REPMEStoolis intendedtoenable

engineerstounderstandhowcurrent products work. _{Additionally, REPMES may}allow

engineeringdesignteams tomore_effectivelyrevisetheirproductdesignsthrough

competitivebenchmarking. The REPMES is illustratedthroughapplicationtocase

studies of a consumerflashlightandan automotivetorqueconverter.

UnlikethefieldofSoftware Reverse_{Engineering(SRE),}thereisnot_currentlya

published standardized procedureto _successfullyimplementreverse _engineeringof

mechanical_engineeringsystems. The REPMESprocessintroduced here differs from

SREinthat the targetforSREistounderstandtheinnerworkingsofacomputerprogram

or system. _However,REPMEShastoaccountforthematerials_{used, the}limitationsof

thesame_{materials, the}physical conditionsunderwhichthesystem mustoperate, the

meantimebetween_{failure,manufacturing}processes and_tolerances, and a_varietyof

otherfactorsnot_typicallyencounteredinsoftware systems.

FollowingtheintroductionandillustrationofREPMES usingtheflashlightcase

study, theREPMEStoolwillbeappliedto theanalysis ofatraditionalmechanical

device, a_{torque converter, to} evaluatetherobustness oftheREPMESinthecontext of a

typical application. Useofthe REPMESwillbedemonstratedtoprovide athorough

structurewillbeemployedtoprovide alistofrecommendedimprovementsto the

Chapter 1 Introduction

Reverse engineeringhas several

definitions,

withthedefinitions of_engineeringand_{re-engineering.}Eachofthese termshas distinct

meaningwithinthecontext ofthis thesis.

"Engineering

andtechnicalknowledgeto solvehumanproblems. Engineersuse _imagination,judgment

and_reasoningto _{applyscience, technology, mathematics,and practical experience.The}

result isthe_{design, production,} and operation of useful objects orprocesses."

[1] Figure

1 shows a_groupof_{early 20th century engineering}studentsfromtheUS _Military

AcademyatWest Point analyzingabridgestructuretoenhancetheirunderstanding. It is

common practicefor engineering_students, and_{practicingengineers, to}learn fromprior

examples ofbothgood andbad designsolutionsto a particular problem.

/

i

mSM

Figure1_Engineeringstudentslearnthroughstudyingexamples ofdesignedsystems[2].

"Re-engineeringistheprocess ofexamination, understandingand alteration of a

system withtheintentofimplementingthesystemina new

form"

distinction between_{re-engineering}and_engineering,forthepurposes ofthis_thesis, isthe

processofiteration. Withinthis_{thesis,engineering}refersto thefirst_rendition,orinitial

release,of a product _design,while_{re-engineering}refersto adesignvariationbasedupon

performance analysis ofthe_precedinggeneration.

However, "Reverse_{Engineering (RE)} istheprocessof_discoveringthe

technologicalprinciples of a mechanical applicationthroughanalysisofitsstructure,

functionand operation.Thatinvolvessometimes_{takingsomething (a}mechanical_device,

anelectrical_component,a software_{program, etc.)}apart and_analyzingitsworkingsin

detail."

[4] Inother_words,reverse_{engineeringhelp}ustounderstandhowa component

functions. Figure 2illustrates ahumorousbutsometimes accuratedemonstrationofhow

testinga product can_helpan engineerbetterunderstandthefunctionsand propertiesofa

product.

DITH WHAT'S THIS RESETBOTTONFOR ?"

"A Technical Data Package_(TDP) isatechnicaldescriptionof anitemadequate

for_supportinganacquisition_{strategy, production, engineering,} andlogisticssupport.

The descriptiondefinestherequired_designconfiguration and procedures requiredto

ensure_adequacyofitemperformance. It consists ofallapplicabletechnicaldatasuchas

drawingsandassociatedlists, _{specifications, standards,}performance_{requirements,}

qualityassurance_provisions, and_packagingdetails. " _[6] Thetechnicaldatapackage

essentiallycontains allinformationrequiredtomanufacture a product.Figure 3shows a

drawing, acriticalelementofa_TDP,ofalower_receivingtubefrom

Savit Corporation.

(fcl8M!" "*'""""

'

IIII* ie*H illIt RUM 6MM St

r,f!p-MT!.'!! -Si

to*MtrUfltH ft HWH IMIMU V*

KM utiviitn

Iruwm..t-uUUlboM.fr* m.i

nMB **"[it)*" **' a*'f'* >c-' ** -i*

rUHH WLjJ.lt<,ltl-.ti*'MU

Tsste*=f_

Figure3_Drawingof a"lower receiving

tube"

takenfromaTechnicalData Package [7].

ATechnicalData Packageismade_upof_manyelements. Onegeneral

specificationforTDPisdescribedbythe militaryspecificationMIL-DTL-31000C,which

requirementsfor preparingatechnicaldatapackage_(TDP)composedofone or more

TDPelements and related TDPmanagement_{data products."[8]}

The militaryspecificationMIL-DTL-31000C _{[8]definesthelist} ofitemstobe included

intheTDPas follows:

Engineeringdrawings

Associated lists

Specificationsthatdefine

Function,performance, interfaces

Physical geometry,other constraints

Processdescriptions

Materialcomposition

Safetyrequirements

Preservationand_packagingrequirements

Testrequirementsdataand_qualityprovisions

Preventativemaintenance system/MaintenanceRequirements

Coordination, interchangeability, form_fit, andfunction information

Three primarymotivations foran engineerto perform reverse_engineeringinclude

(1) expansionofknowledgeand_{understanding,(2)}competitivebenchmarking,and₍₃₎

replacement of alostorincompletetechnicaldatapackage.

Competitive_benchmarkingispracticed_bymost modem_engineeringandproduct

developmentorganizations inaneffort_{to continually}improvetheirproducts anddesigns.

Theancient ChinesewarriorSun Tzutaughthismento "knowyourenemy"

before_going

into battle. Forif"youknowyour_enemyandknowyourself,"

feartheresult of ahundredbattles." _{But, SunTzu warned, "Ifyouknowyourselfbutnot}

the enemy, for_{every victorygained you will also suffer a}defeat." [9]

Identifyingthe_product, service and process from_topcompetitorsand_comparing

it with your ownisthe

key

onlyillustratethefeaturesof another company's productsbutalsothe_engineeringand

customer's satisfaction oftheproduct_bysurveys conducted and explored_bythatspecific

company.

Oneexampleofa modern corporationthatconducts competitive_benchmarkingis

General Motors(GM). AsofOctober_2006,"GM isthelargestautomobilemakerinthe

world"

[10],sellingmillions of cars per year. Whattoolsdo corporations_employtolearn

thedesiresofthecustomersintheirmarket?Howdolargecompaniesunderstandthe

engineeringdesignsof productsfromothercompanies?Howcan manufacturers reduce

thecosts associated with productionfromoneyearto thenext?Reverse engineeringand

benchmarkingare essentialtoolsusedin answeringeach ofthesequestions.

General MotorsCorporation, like_manyother majormanufacturers, hasaformal

programfor_benchmarkingproduct made_bycompetitors.GMoperatestheVehicle

Assessment and_{BenchmarkingActivity}(VABA),andpreparesinternalreportsfor

dozensof vehicles annually. Forexample, intheinterval betweenJanuary

-May 2006,

GMpurchased a$49,000 Silver Lexus RX 400h hybridsport_utilityvehicle_(SUV),

Figure 4 Lexus- _phototakenfrom

content source_[11]

The Lexus _SUV, manufactured_byToyota,is_highlyregardedas ahighend

vehicleinthe SUVmarket. GMdisassembledtheirLexus SUVattheirGM Technical

Center located in_Warren, Michiganinan efforttounderstand_everyaspectof_{the vehicle,}

ranging fromtheparts_{used, to estimating}theproduction cost. It isreportedinthe

literature _[12]theGMconductsteardownsontheirown vehicles aswellasthevehicles

oftheircompetitors suchas_{BMW, Mercedes, Hondas, Lexus, Toyota,Chryslers,} and

Ford. Itisestimatedthatabout_twentyvehicles aresubjectto theprocessknownas a

"fulltrim-sawcut"

whichistheprocess of_cuttingdoors,roofpillars andfenders in

100-mm-wide cross_sections,whicharethenscanned intodigitalblueprints foranalysis_by

engineers. Results for 2007include_ChevyMalibu Hybrid₍₂₀₀₇₎which willhave 822

propulsion parts compared withthe 1,432partsthatmake_uptheToyota Prius. _[12]

Isthere_anyreasonthata_companyusesreverse_engineeringonitsown product(s)?

Isthatpossible? _Whywould a_companyundergothatprocedureinternally? Engineers

use reverse_engineeringto theirown productsasatoolwhentechnicaldataare_missing

andto_verifydesignintentoftheirengineeringstaffthroughindependentvalidation. One

waytorecover_missingtechnicaldataiswiththehelpof reverse engineering. Agood

missions_byNASA

during

the moon, the

Apollorocket usedisshowninFigure5. Ifwe wanttoaccomplishthis task_again, whatis

thefastestwayitcouldbe_{accomplished?}

First, takinginto accountthatatthe timewe

traveled to the moon, theoriginaltechnical_data,andtheTechnical DataPackage_(TDP)

was not created on computersbecausetheIntel 1103 Computer_Memory(Theworld's

firstavailabledynamic_{RAM chip)}andIntel 4004_{Computer Microprocessor (The first}

microprocessor)were availablein 1970and 1971 _respectively

-well afterthedesign

phase ofthe 1960'swhentherelevant _{engineering drawingsand analyses were compiled.}

131

mm

l-M-WII

59 M

/ 1

11

1 '

'

^1

**- _{:. \}

Figure 5 Apollo Rocketfromthe1960's_leavingtheNASA headquarters [13].

Second,atthecurrentdateof_2006, it isexpectedthat_manyoftheoriginaldesign

engineers'

team_maybe deceasedor atleastretiredfrompractice. _Third, changes in

design_{specifications, drawing}practices, andtechnologiesforreproductionhaveevolved

dramatically

thecasethat thebest_waytobegin_designinganewlunarmission vehicle wouldbeto

reverse_engineeringtobetterunderstandhow_theyfunctionandthencomparethe

knowledge withthe_technologywehaveavailabletoday.

Engineerscan use reverse_{engineeringtoimprovethemselvestobecome better}

engineers, by

learning

attheRochester Instituteof

Technology

2006,Professor Landschoot

used reverse_engineeringwith students enrolledinthecornerstonedesignclassto

understandhowa solenoid_valve,similartothoseillustratedin Figure_6, functionsand

what fabricationprocess were used intheirmanufacture.

"'_j J'.y\fc

Figure6 SolenoidValvesmanufactured_bytheG.W. Lisk_Companyforapplications such as_vehicle,

aerospace, marine,etc._[14]

InordertounderstandthefabricationprocessProfessor Landschootwas required

togoto theGW Lisk_Company,since_theyweretheactualcreatorsofthesolenoid valve.

Thesolenoid valvethatProfessor Landschootis_{experimenting}withisusedto teachhis

studentsinthe CornerstoneDesignclass. Thereverse_engineeringprocessesthat

Professor Landschoot is_using to teachtheCornerstone Designstudents include:

functionaland economic_analysis, analysis ofits structure,functionand_operation,

disassembly

Thisthesiswill focusondevelopmentofanew standardprocesstoimplement

referredto asReverse_{Engineering Processes in Mechanical}

EngineeringSystems

(REPMES). Thebaselineversion ofREPMESwillbe basedupon aninvestigationof

relevantliterature fromthesoftware reverse_engineeringand mechanical and electrical

designfields. Agraphical representationofeach reverse_engineeringmethoddiscussed in

theliteraturewillbe_{created, to} summarize and_illustratea_varietyof reverse_engineering

processes. Commonelements willbe inferred fromtheliteraturereview_{investigation,}

resulting inthepreliminaryversion of_{REPMES. The priliminary}versionof_REPMES,

REPMESi,willbeappliedto a simple product- theRayovacflashlightV2D-B. This

flashlightwas chosenbecauseitpossessesdetailedcomponentsallwithin a simple

structure. _Moreover,sinceits inventionin 1_898, theflashlight hasundergone various

changes and_{developments, specifically in}termsofthe_technology,thematerial used as

well asthe_relationshipbetweenhumansandtechnological systems- _ergonomics.

Using

knowledgegainedthroughanalysis ofthe _{flashlight, REPMES2}willbe developedas a

directresult ofthe analysis ofthe_{flashlight, REPMES2}willbeadirectresultofthesteps

unforeseeninthedevelopmentofREPMESi. Oncereverse_engineeringoftheflashlight

is_complete, REPMES2will_inevitablyneedtobemodifiedinordertoaccount for its

applicationtoareal-worldproduct. It isimportanttonotethatREPMES2mustbe

generic enoughfor_anyproduct'sanalysis,yetdetailedenoughtobea_truly

implementableprocess. This improvedversion willtakeintoaccount specific_tools,

technologies andtheories thatwill_applyto theproduct.

Followingthedevelopmentoftherevised_version,REPMES2willbeusedto

conduct a reverse_engineering analysis ofatorque converter, a_{fluid-coupling}deviceused

Thetorqueconverterisan appropriateexamplefor_testingthe_REPMES,because it isa

fullymechanical_{component;having}mechanical and_{design features}with unique

manufacturingconsiderations, and material_propertyconstraints.Justas withthe

flashlight,the torqueconverter willbe_{carefullydisassembledto thelastremovable}

component_{(non-destructively)} andtheneach ofthesecomponentswillbestudiedin detail usingthe_REPMES2procedure.Thedevelopmentof a comprehensivetechnical

datapackageincludesa3-D solid model and_drawingpackage with_fullydetaileddesign

and mechanical _features, and material propertiesbasedonthecoordinates obtained from

aCMM_{(Coordinate-Measuring}Machine). Uponcompletionofthe torqueconverter case

study, afinalversion ofREPMES_{(REPMESFinai)}willbeproposedforuse with a wide

varietyofmechanical products. The resulting REPMESwillbeatoolusefulfor

engineers_wishingto expandtheirknowledgeof productdesign, conduct competitive

benchmarkingof abaselineproduct against competitiveproducts,and _{for replacing lost}

Chapter2 Literature Review

Before_introducingtheReverse

Engineering

Systems, one mustfirst become familiarwiththevarious resourcesofreverse

engineeringprocesses. Thischapter will provide anoverview ofreverse_engineering

processes_beingapplied inbusiness, _{software, mechanical,mechatronics,} industrialand

otherfieldsof applications. Detailed informationonhowreverse_engineeringisapplied

tobothtangibleitems(suchas_products)andnon-tangibleitems (suchas processesand

software)arediscussed

Thoughreverse_engineeringcanbe_{highlybeneficial,}it can alsobeusedinmore

antagonisticterms. _{Reverse engineering may be}usedfora wide_varietyofapplications.

For_{example, the paper,} "Data Rights Provisions Do Not Protect Your Products inDoing

BusinesswiththeGovernment Be Alertto theNeedtoProtect YourselfandYour

Products Against 'ReverseEngineering'"_byJacobB. Pankowski _[15],isaboutarecent

lawsuitcase_study,Night Vision Corporationvs.UnitedStates. Thecase_study

demonstrates how contracts withtechnicalitiesareessential withinnovativeproducts, in

lightofreverse engineering. Night Vision Corp. (NVC) introducedanewtypeof night

vision gogglesto theUnited States Air Force. The Air Forceallegedlydecidedto take the

physicalproduct andpassitontoNVC'scompetitortoreverseengineertheproduct.

Thoughacontractwasmadebetweenthe two parties, thecontractonlyprotectedthe

company'stechnicaldatarights,and notthephysicalgogglesthemselves.NVCsuedthe

Air Forcefor_passingontheirproduct.Thegovernmentdidnotconsiderit as

infringement sincethenight vision goggleprototypesare notconsideredtechnicaldata.

initiallywithNVCbecause itwas not_{included inthewritten agreement.Thecourt}

indicatedthatNVCshouldhave_{pursued a patent ontheproducttoavoidduplicationof}

theproduct or_allowinga competitortoreverse engineertheproduct. _{Reverse engineering}

is_{widely promoted,} forexample_bythe_government,becauseitprovides competition

within companies and also an_{opportunity forinnovative}productstoemerge. When

making anytypeof contract or agreement with abusinesspartneritisadvisedthatall

technical_data, data_rights, intellectual_property, and physical products are protected.

2.1 ApplicationofReverse_EngineeringMethods in Business

Reverse engineering isa processtounderstandhowa system works. Severaltools

havebeendevelopedtosetthe_{functionality}ofa_{business,however,}tobeabletosetthe

business _{functionality}it isrequiredto firstunderstandthebusiness. Businessescaterto

customer needs andtobeableto_{satisfythose needs,they}needtoanticipateandadaptto

customerdemands. _{The proceeding}twopaperswill showan exampleofhowbusinesses

mayreact_usingreverse_engineeringtoanticipate and adapttocustomerdemands. The

first_paper, "Processreverse _engineeringforBPR: aform-basedApproach"_ByK. H.

Kim_[16] describesand presentstheEnterprise Process Reverse_{Engineering (EPRE)}

methodfor_analyzingbusinessprocesses and_supportingprocess redesign_tasks, sets a

business functionality. Thesecondpaper, "Reverseengineering-moderntoolfor

product-planning"

byB. Schumacher _[17],describes how hewantedtofindout aboutthe

advantages and limitationsofReverse_Engineeringduringstages ofdevelopmentand

Itis importanttonotethat thereisone major challenge

facing

Reverse_Engineeringimplementation. The_existingbusinessprocesseshavetobe

understoodto enablethedesignteam to

identify

The Reverse_Engineeringpart of

(EPRE)

described inFigure7._Accordingto_Kim, thefirst_{step in}businessprocess redesignisto

define forms andform_fields, which requirestheidentificationand analysisofthe

candidatebusinessprocessestobe_{redesigned, along}withtheirrelated organizational

units. Kim'snext_stepisto _identifyfield set operationswith fieldtype. In_{this paper,}

FieldSet Operation_(FSO) isdenned as a setofactivitieswhichprocesses fromone or

more fieldsandisperformed at a singlelocation_duringa singlesessionfora specific

customerservice(Output_{WaitingTime, Processing Time,} etc).

Stage 1: Forui Analysis

Define Formsand form fields

Idvutifvfield s e i operations withfieldr\pc

p Stage 2: rocessMot Seaeratloii lei

Generate EPC Diagram

Figure 7 Formanalysis andProcess ModelGeneration,inspiredbyKim[16]

Thesecond stageofKim'sBusinessProcessRedesignmethod requirestheuserto

generatetheinitial EventProcessChain_(EPC)diagram basedontheprocess-related and

selection order needstobeestablished. EachFSOcan_{be insertedby}theusertosearch

thelargernumber of related commonfields.

C"ti.nilDll..ti

Rrtnm |**mttt"TMrailMJOf

H'

1

1-M-. Km

1" '

f

"

HcfivtrafKid

1

,,md ( i'

n ii]

II'...,. t rater

M<

Process Cycle Tunc 2bottn

\V,tlt (^J) :event process. <^> hranth. U

Figure 8 EventProcess Chain Diagram from Kim_[16]

Figure_8, from Kim_[16] illustratesan exampleofEPC as a simulationofa

hospitalvisit. In_{this example, the}fieldset operations isrepresented_bythe

"Consultation"

room, the"LobbyArea", andthe_"PharmacyCenter."The setofactivities

-event, process,branch, and wait are represented_bya_circle, a_rectangle, adiamondand

a"W"respectively. Inthis simulation, the totalprocesstimeistwo_hours;three

processes,three events, andthree_{different waiting}times. The businessprocess event

starts whenthepatient entersthehospitalto the_lobbyarea, theregistrationprocesslasta

totaloffiveminutes. Thepatientthenwalks overto theconsultationroomtowaitfor60

minutes, followedby being consultedforfifteenminutes. After receivingthe

ten minutes, fiveminutes_waitingandfiveminutesforthepayment process. Thepatient

thenentersthe_{pharmacycenter, to} putinthemedicinerequest and wait forthe

prescriptiontobe_filled,foratotal timeof30minutes.Atthispointtheentire event

processiscomplete. Kim'sreverse_engineeringprocessdemonstratesthatREcanbe

applied not_{only apply}to tangible_products,butalsoto_manytypesofbusinessesand

industries. Thisalsodemonstratesthatinformation foraTDPcanberepresented_by

processtoolsforexampleEPCdiagram.

Anotherexampleofwhere reverse_{engineering is}appliedtoa_business,is

"Reverseengineering-moderntoolforproduct-planning"

byB. Schumacher_[17];where

Schumacherrealizedthat_manyindividualsusethismethodbutasystematicdescription

islacking. Scientificanalysisof_existingproductisneeded inorderto achieve a_new,

improved, and cheaper productthatismore market-oriented.

Theprocessofreverse_engineeringas shownin Figure 9startswiththe"Scientific

Analysisof_existing

products."

In_{this paper,they}concentrateonthe technical_functions,

featuresand innertechnical_dimensioningofa product. _Theythencontinue with

documentation. Thethird_stepis"NewPlanning,"whichconcentratesonthemarket areas

(cost_{attractive, innovative,}reliableandrapid). Inother_{words, this step}concentrates

primarilyonwhat customers want._Next, a"Product

Specification"

isneededas abase

forthenewplanning.

The fourth stepisProduct,thisiswhere aprototype ofthenewproductis

obtained, andproductionisstarted. Itis importanttomentionthat thispaperpresentsa

graphical representationoftheappropriateamount oftimedevelopmentalelements

theircase_{study, thefirst groupincludeda}

keyboard,

housing-injection_mold, and_assembly, all ofwhichtook 16weeks. Thesecond_{group included}

testingand_trimmingwhichtookatotalof4weeks.Thelast_groupincludedpurchase of

components and_assembly, whichtookatotal3weeks.

ScientificAnalysis

of_exisingproducts

I New_Planning

Product Specifications

Figure 9 REas atoolforproduct_planning,inspired_bySchumacher_[17]

2.2ApplicationofReverse_EngineeringMethods in Software

AnotherareaforReverse_Engineeringthathas increased_tremendouslyis

Software:

including

CodeVisualtoFlowchart. Thosethreesoftware programs_helpdevelopersunderstand

source code andthenvisualizeitthroughflow chart modeling. SearchVB statesthat

"software designerusesRationalRose_{to visually}create(model)theframework foran

application_{by blocking}out classes withactors(stickfigures),use case elements_(ovals),

objects_(rectangles) andmessages/relationships (arrows)inasequencediagram_using

drag-and-dropsymbols."

constructed andthengenerates codeinthedesigner'schoice of_C++,Visual_{Basic, Java,}

Oracle8, CORBAorDataDefinitionLanguage." [18]

Thenext six papers will show_{differentapproachestosoftware reverse}

engineering. Thefirst_paper,"Reverse

Engineering

Software"

byHildreth_[19],discussedwaysto _developa methodto_applyreverse

engineeringtoprocess-control software. Theresults providedknowledge about what a

systemis doing. Thesecond _{paper, "Analyzing}theapplication of a reverse_engineering

processto arealsituation"

byF. Abbattista_[20],describesamodelinwhichthereverse

engineeringprocess, appliedtoa software_system, interactswiththedocumentationofthe

software systeminorderto_mutuallyimproveone another.The_{third paper,} "Domain

analysis andreverse

engineering"

byJ-M DeBaud _[21] demonstrateshow Domain

Analysiscanbeusedas atoolto aidthecomprehensive processofreverse engineering.

Itdiscussesthe_relationshipofapplicationdomainand reverse_{engineeringbypresenting}

two case studies. The fourthpaper,_{"Characterizing}Reverse_EngineeringProcess

component _methodology(CREP)"_byMaria Tortorellaand Giuseppe Visaggio _[22] isa

methodto _formalize, characterize and evaluatereverse_engineeringprocess components.

The fifthpaper,"Areverse_{engineeringmethodology to}reconstructhierarchical data flow

diagrams forSoftwareMaintenance"

byP. _Benedusi, A. _Cimitile, andU De Carlini _[23]

describesthe_methodologyusedtodefineareverse_engineeringprocessthathas been

employedinanenhancement maintenance operation on aPascalsoftware system The

lastpaper, "ReverseEngineering: A

Roadmap"

byHausiA. Mulleret al. _[24], presents

fourperspectivesinthefieldof reverseengineering toprovide a_roadmapforother

Hildreth's _[19] goal wastomaintaina systemin_control, which means

defining

system_{functionality}inalanguagethatisspecificto theproblemdomain. Theprocessin

Reverse_Engineeringoftheprocess-controlsystemhas four_components, asdescribed

below_byFigure10. Theseincludethe_{process, sensors,} actuators and controller.

Process

State

Estimation

Supervisory

Control

Error

Detection

Corrective

Command

Computation

Figure 10 Processcontrol stepsforRE,inspired_byHildreth [19].

Thefirst_stepistheprocess state estimation. In_{this step, the}processismeasured

and_operatingconditioninputsare usedtodetermineanestimateofthecurrent state of

theprocess. Thesecond_stepisthe_{SupervisoryControl,} whichisbasedonthereview of

computers outputs. Herecontrol andprocess engineers would adjustset points inorderto

optimize_efficiency, fine_{tune control,} and maintain system operation within specified

limits. _{The ability}of computerstomake such adjustments automaticallyisreferredto as

supervisorycontrol.

Thethird_stepisErrorDetection. Therole oftheerrordetectoristodetect

points. Thefinal_stepistheCorrective_{Command Computation.} Inthis _step,therole of

thecontrolleristodeterminethecorrective commandneededto changethemanipulated

process variable sothat thedeviation iswithinacceptedlimits.

Tobetterexplainthis_process, let's saythata systemis set with a certain range.

Duringthesupervision_stepoftheprocess, it is detectedthat thesystem surpassesthe

range; thenext_stepwillbethat thesystemis correctedtomaintain control. _Realizing, a

systemcontrolas a continuous reverse_{engineeringprocess,} dueto thefactthat the

systemhastobeunderstoodtobecorrected or redesigned.

Thesame occurs whenindustrialand_{manufacturing} engineers analyze a system

process anduse process capability. "Process_Capabilityisrequiredtobeused_byTS

16949 (ISO TechnicalSpecification). _{Process capability}comparestheoutputof an

in-control processto thespecificationlimits_{byusing capability indices:} a process_capability

indexusesboththeprocess_variabilityandtheprocess specificationstodetermine

whethertheprocessis 'capable.'Thecomparisonismade_{by forming}theratio ofthe

spreadbetweentheprocess specifications(thespecification_"width")to thespread ofthe

process_values, as measured_bysix process standarddeviationunits(theprocess "width").

Thereare several statisticsthatcanbeusedtomeasure_{the capability}ofaprocess: _Cp,

Cpk, Cpm. _{Most capability indices} estimatesarevalid_{only if}thesamplesizeusedis

'largeenough'.Largeenoughis_{generally thought to}beabout50 independent datavalues.

The_{Cp, Cpk,} andCpmstatistics assumethat thepopulation ofdatavaluesis_normally

distributed."

[25]. _Cp istheprocess_capabilityand Cpkisanindexwhichmeasureshow

close a processis_runningtoitsspecificationlimits. Generally,typicalCpkthatisabove

istheprocess_capabilitymeasured againstperformanceofthe target. _Alongwiththeseare

twolimitsthat separate randomvariationandnonrandomvariation. Thelargervalue is

theupper controllimit_(UCL),andthesmallervalueisthelowercontrollimit (LCL). A

sample statisticthat fallsbetweenthosetwo limits suggest randomness andthoseoutside

values are not randomness.

LSL

Process Idcontrol rLS

Cp- _m-X

6xO

Cpk=1.44

Mean=9.20 inches

O=0.3inches

LSL=7.50 inches

l'LS=10.50 Inches

Figure 11ExampleofProcesscontrol_{step forRE,}whereLSLandULSarethelimitssettobein

control

As an_example, a_{manufacturing}team_(MT)ofthe_{company AB had detected}that

theproductionline_"KP12", in_July,producedthreeout of25 _laptopscreens with9.53

inchesinwidth. Backin_May, theprocesshada meanof9.20inchesand a standard

deviationof0.30 inches. The lowerspecificationlimitwas 7.560inchesandtheupper

specificationlimitwas 10.50incheswith aCpk=1.44(Figure 11). AftertheMT analyzed

the process,theydeterminedthattheproblemwasthatmachineA(forproductionline

"KP12")was notcalibrated.Afterthemachinewascalibrated and _{corrected, the}system

understandhowa systemworks sothatsuccessful completion of_supervision,detection

and correctioncouldbeaccomplished.

Fromanother_prospective, F.Abbattista _[20] applied reverse_engineeringtoa

software systemthatinteractswiththesoftwaredocumentation. The_followingprocess is

describedinFigure 12.

Inventory Software

System

iH

Reconstruct

Logical Level

ofData

Jilz.

Analysisof

Existing Information

vkl Reconstruct

Logical Level

ofPrograms

\/

Abstract

Data_Modeling

JJd

Abstract

Functions

Modeling

Figure 12 REprocessanddocumentationforsoftwaresystem,inspiredbyAbbattista[20].

Thefirst_stepistheInventorySoftwareSystem Its inputscontaintheSoftware

returningoutputs as Structure ChartsandLogicalData Pre-models. Thesecond_{step is}to

Reconstruct LogicalLevelofData. Itsinputs consist ofDataDescriptionsandLogical

Data Pre-models. _Duringthis step, thedata descriptions are analyzed againstthelogical

datapre-models obtained fromthe_inventory, and a logical datamodelisgenerated.Its

outputs areinthe formof aLogical DataModel.

Thethird_{step is}theAnalysisof_ExistingInformation. Itsinputsare

DocumentationandExperienceintheField. Thepurposeofthis_step isto_identifythe

expectedfunctions intheprogram_beingreversed _usingtwo typesof_information; static

(documentation) anddynamic_(experience)knowledge. Theoutput isanExpected

Functions List.

The fourth stepisto Reconstruct Logical LevelofPrograms. ItsinputsareCode

and Structure Charts. In_{this phase,}bothdead dataanddead instructionsareidentified.

Thesearedatathat are not used_bytheprogram andinclude instructionswhichcan notbe

run. The dead instructionsarethenerased from_{the chart,} andalogical functionsmodel

isgenerated. Theoutputs areLogicalFunctions Models and Dead Data.

The fifth stepisAbstract Data Modeling. Its inputsareLogicalDatamodels and

Dead Data. All dataisanalyzed and organizedinto aconceptualdatamodel. The final

outputisaData Conceptual Model. Thesixth_stepisAbstract Functions Modeling. Its

inputsareLogical Functions _Models,DataConceptualModels, Expected FunctionsLists

andDocumentation. Thepurpose ofthisphaseisto analyzethelogicalfunctionsmodel

againsttheexpectedfunctionsandthedocumentationinordertocreate aconceptual

model_accordingto thedataconceptualmodel. Theoutput produces afinal Conceptual

Ontheother_hand, J-MDeBaud _[21] discussesthe_relationshipofapplication

domainand reverse_{engineeringbypresentingtwocase studies. Thefirst case}

studyuses

adomainmodeltoguidethereverse _{engineeringeffortby}

applyingobject-oriented

frame-workto understandtheconceptofthedomain. Thesecond one studieshowreverse

engineering canbeusedtobuildadomainmodel.

Object

-oriented

domain model

representation

IdentifyPatterns

-Feature expectations

Figure 13 REprocess_byapplyingobject-oriented_{frame working}tounderstandtheconcept ofthe

domain,inspired_byJ-M DeBaud_[21]

Thefirstcase_studyuses object-oriented_technologyasthedomainmodel

representation mechanism as a referencetoguidethereverse_engineeringmethod(Figure

13). Thistechniquemadeitpossibleto _identifypatternsthatreflected a purposetokenin

thesource code. Object-oriented frameworksprovide a clear and normative structureto

guidethereverse_engineering effortthroughfeatureexpectations and purposepatterns.

. . . .

Derived Expectations [rind Stereorvpical Cues

. J \ ! >

^

ImplementationofDesign

Inthesecond case_{study, the targetprogram was reverse}

engineeringandthe

domainmodelthatresulted was studied. Themethod usedtoreverse_engineer, (Figure

14)theprogramwasSynchronized Refinement. _{Thistechnique} analyzestheprogramtext

frombottom_{up, looking}forstereotypical cuesthatsignal implementationofdesign

decisions. Italso synthesizes an applicationdescription fromthe_{topdown,using}

expectationsderived fromthevariousdomainsrelevantto theprogram.

TortorellaandVisaggio's _[22]methodto_formalize,characterize and evaluate

reverse_engineeringprocess components usestheCREPmethod.CREPmethodshave

two phases; thefirstoneformalizestheprocess _components,andconstructstheprocess

models, whilethesecond phase characterizestheprocesscomponents,_highlighting

then-most peculiar concepts and_groupingthehomogenousinformation. The_followingprocess

is described inFigure 15.

ModelDocumentation

Build Process Model

J&. Modify Process Model

7F Inconsistencies

4

("

Modified Process \|/Model Validate ProcessModel

iki Characterize Process Model

Figure15_{Characterizing}andevaluating REprocesscomponents,inspiredbyTortorellaand

ThefirstCREP _StepistheBuildProcessModel_phase,whichformalizesthe

reverse_engineeringprocess componentstoanalyzetheordertorepresentthemina

uniformway. Thistaskreceivesinputofallthedocumentationavailable oftheprocess

componentstoanalyze and compareto

develop

secondmodelistheValidate Process Modelwhich analyzes and checkstheprocess

modelsobtainedintheprevioustask to _{verify if}internalconsistencies exist. Thethird

modelisthe_ModifyProcess model which modifiestheinconsistencies_possibly

discovered_duringtheprevioustask._{The fourth step}is CharacterizeProcess _Component,

whichdeterminestheevaluation schematicofthereverse_engineeringprocess

componentswhose process modelshave beenobtainedintheprevious step.

Benedusi,Cimitile, and De Carlini _[23] describesthe_methodologyusedtodefine

areverse_engineeringprocessthathas beenemployedinan enhancement maintenance

operation on aPascalsoftware system. _TheydefinetheReverse_{Engineering (RE)}

processinthreephases as showninFigure 16. Thefirstphase consistsof_(i) analysis of

thereasonsforwhichitwas set_up,(ii)thereferencesoftwaremaintenance and

AnalyzeRequirementsand

SoftwareProductioncycle

Define Goals

V

Define Models

and

Data Structures

2nJz Define

Information Abstractors

Figure 16 RE_Methodologytoreconstructdataflow_diagrams,inspired_byBenedusi _[23]

Thesecondphaseistodefinemodelsonthebasisofthegoals. Thesearethe

specificationfunctions that theREprocess mustdevelop: _{1)identifying}theoperationsto

becarried_out, and₂₎theinputson whichtowork andtheoutputstobeproducedfor

each function ina clear manner.

The last phasein REprocessdesign isthedefinitionof aninformationabstractor

thatcan_{automatically}produceor supporttheproduction ofthedocumentstobe formed

and aconceptualdescriptionoftheinformation_theycontain.

The lastpaper_byMulleret al. _[24],presentsfourperspectivesinthe fieldof

reverse_engineeringtoprovide a_{roadmap for}other engineers(Figure 17). Also,the

authors offer peer support as_theyfollowthesame pattern astheother papers.Thereverse

(Data)

Catalog

w

L'_

AnahsingData

/ ~

Design Team

J Logical Data Model

"

(

")

NX _yj

Conceptual Design

Re design

Figure 17REstepstoanalyze_{data for software, inspiredby}Midler_[24]

Inthefirst_field, "DataAnalysis"

thedesignteam_(engineers,domain _expert,

developer, etc.)analyze_{the code,}schema_catalog,obstacledocumentationand dataso

theycanhaveabetter understandingofhowtheprocess shouldbecarried out. Thenext

field, "LogicalDataModel"

isonethat involvesTaxonomy. _Taxonomyisa classification

ofthings_{(answers, February10, 2006),}sointhisstage organization and classificationof

theanalysesis done for better_{understanding}and usability.

Thethird _{field,"Abstraction",}isproducedthroughatransformationofthe

analyzedlogical datamodel andthefeed backoftheDesign Team. Inother_words,it is

thedesignverification ofthedata.Thelastfield istheconceptualdesignwhichinvolves

all areasthatare concernedwith re-design and_{re-engineering}procedure.Inmechanical

engineeringterminology,thiswillincludetheDesign for_{Manufacturing}and_Assembly

2.3 ApplicationofReverse

Engineering

Typicalapplicationformechanicalcomponentstoimplementreverse_engineering

isthrough_usingvarious computer aidedprogramsand mechanical systems. Examplesof

computer aideddesignprogramsinclude Pro-Eand Solid_Works, which providedetailed

drawingsthat are_manuallyinputted intothecomputer. Examplesofmechanical systems

include Coordinate_MeasuringMachines_(CMMs)andRange_Imagingmachinesthat

move a_measuringdeviceto determinethecoordinatesofpoints onthesurface ofa

piece/componenttoobtain atechnicaldescriptionofthecomponent.

Thenextfourpapers willdiscussreverse_engineeringappliedto a component

using computer aidedand mechanicalsystems. Thefirst_paper, "Reverse engineeringof

mechanicalcomponents withinacomputer-aideddesign/computer-aided_{manufacturing}

environment"

byV. Kalra_[26], definesthereverse_engineeringprocess within a

computer-aided_{manufacturing}environment_usingcomputer-aideddesign. Thesecond

paper, "On generating solid modelsof mechanicalpartsthrough_fuzzyclustering" by

Girish PhansalkarandRajesh N. Dave _{[27], describes how using}reverse_engineeringis

usedtogenerate asolid model. The_{third paper,} "Feature-basedreverse_engineeringof

mechanical parts"

byWilliam Thompsonet al. _[28], describesaprototypeof a reverse

engineeringsystem which uses_{manufacturing features}asgeometric primitives. The

fourth_paper, "Reverse Engineering: A ToolforProcess Planning"_byAbella Daschbach

andMcNichols _[29]describes howtousethe_{Coordinate-Measuring}Machines_(CMM)as

reverse_engineeringtools.

Kalra[26],definesthereverseengineeringprocess withina computer-aided

engineeringprocess consistofmeasurementofthepart_{geometrybya contact or}

non-contact measurement_device,the_{developmentof a computer aided geometric modelfrom}

themeasurement_data, and possible_{engineeringrefinements}ofthepart_design,

Developmentofthe_{manufacturing}planincludes_selectionofmaterials andtheactual

production ofthepart as shownin Figure20.

Component

^\y

Measurementof

thepart_geometry

~ls

GeometricModel

ik:

EngineeringRefinements

J

jss

(ManufacturingPlan

JsJ^

Production

Figure20Reverse_engineeringof mechanical componentsforCAM/_CAD,inspired_byKalra [26].

Toillustratethisprocess asan_example, let'ssupposePersonAwho lives in

Californiawantsto produce a_product,andis forcedtoget informationabouttheproduct